Plated steel sheet with quasicrystal

ABSTRACT

A plated steel sheet with a quasicrystal includes a steel sheet and a plated-metal-layer arranged on a surface of the steel sheet. The plated-metal-layer includes, as a chemical composition, Mg, Zn. The plated-metal-layer includes, as a metallographic structure, a quasicrystal phase. A Mg content, a Zn content, and an Al content in the quasicrystal phase satisfy 0.5≦Mg/(Zn+Al)≦0.83 in atomic %. In addition, an average equivalent circle diameter of the quasicrystal phase is equal to or larger than 0.01 μm and equal to or smaller than 1 μm.

TECHNICAL FIELD OF THE INVENTION

The present invention relates to a surface-treated steel sheet which is excellent in corrosion resistance. Particularly, the present invention relates to a plated steel sheet with a quasicrystal.

RELATED ART

The quasicrystal is the crystal structure which was firstly discovered in 1982 by Dr. Daniel Shechtman, and has an atomic arrangement with a polyhedron with 20 faces (icosahedron). The quasicrystal is known as the crystal structure which has unique rotational symmetry not to be obtained by general metals and alloys, is a non-periodic crystal structure having fivefold symmetry for example, and is equivalent to a non-periodic structure represented by a three-dimensional Penrose Pattern.

After the discovery of the new arrangement of metallic atoms, that is new crystal structure, the quasicrystal having the quasi-periodic structure and having the unique rotational symmetry has received a lot of attention. The quasicrystal has been generally obtained by a liquid quenching method in the past, although it is found that the quasicrystal can be obtained by a crystal growth method in recent years. The shape thereof has been restricted to powder, foil and chip, and thus, it has been very rare to apply the quasicrystal to a product.

Patent documents 1 and 2 disclose high strength Mg based alloys and producing methods thereof. The Mg based alloys have a metallographic structure in which the hard quasicrystal phase having a grain size of tens to hundreds of nm is dispersedly precipitated, and thus, the Mg based alloys are excellent in strength and elongation. The patent documents 1 and 2 utilize the properties such that the quasicrystal is hard.

Patent document 3 discloses a thermoelectric material using Al based quasicrystal. The patent document 3 utilizes the properties such that the quasicrystal is excellent in thermoelectric property. Patent document 4 discloses a heat-resistant catalyst whose precursor is a quasicrystalline Al alloy (Al based quasicrystal) and a producing method thereof. The patent document 4 utilizes the properties such that the quasicrystal without a periodic crystal structure is brittle and fracturable. As described above, in the prior inventions, the quasicrystal is often dispersed as fine particles or the quasicrystal being fine particles is often consolidated.

As another application different from the above inventions, patent document 8 discloses a metallic coating for cookware containing the quasicrystal. In the patent document 8, the coating excellent in wear resistance and corrosion resistance to salt is applied to the cookware by plasma-spraying the alloy powder containing the quasicrystal which consists of Al, Fe, and Cr and which is excellent in corrosion resistance.

As described above, the Mg based quasicrystal is utilized as the materials excellent in strength, and the Al based quasicrystal is utilized as members which is excellent in strength, thermoelectric materials, and coatings for cookwares, or the like. However, these utilizations are limited, and the quasicrystal is not always utilized in many fields.

The quasicrystal has excellent characteristics derived from the unique crystal structure. However, the characteristics thereof are only partially investigated, and the quasicrystal is not widely applied to industrial fields at the moment. The present inventors have tried to improve the corrosion resistance by applying the quasicrystal which is hardly utilized in the industrial field to a plated-metal-layer of a surface-treated steel sheet.

In general, in order to prolong a useful life of steel sheet, the steel sheet is subjected to surface treatment such as metallic plating, paint coating, conversion coating, or organic film laminating in order to ensure an anticorrosive function to a certain extent. In the many steel materials used in fields of automobiles, consumer electronics, building materials or the like, the metallic plating is mainly applied. The plated-metal-layer provides, at a low cost, both barrier protection in which a base metal (steel substrate) is shielded from outside environment and sacrificial protection in which the layer is preferentially corroded as compared with the base metal.

There are various methods to industrially form the plated-metal-layer. In order to make the plated-metal-layer thick, spraying, hot-dip plating or the like is preferable. In order to uniformly form the plated-metal-layer, sputtering, ion plating, evaporating, electro plating or the like is preferable. Among these methods, the hot-dip plating is widely applied, because it is possible to massively and economically produce the steel materials with the plated-metal-layer.

In the electro plating, deposited metals are limited, and thus, the elements included in the plated-metal-layer are limited in general. In the methods such as the spraying and the evaporating in which the plated-metal-layer is formed by using reactions such as melting, evaporation, deposition, and solidification of metals, it is possible to form the plated-metal-layer as with that formed by the hot-dip plating in theory. However, each metal has specific melting point and boiling point, and thus, the difference between chemical compositions of the used alloy and the formed plated-metal-layer tends to occur in the spraying and the evaporating.

Since it is possible for the hot-dip plating to form the plated-metal-layer whose chemical composition is about the same as that of the used alloy for the hot-dip bath, the hot-dip plating is well suitable for forming the plated-metal-layer which has predetermined chemical composition as compared with other forming methods.

At present, conventional surface-treated steel sheets which are industrially available are mainly those with the plated-metal-layer of Zn-based alloy or Al-based alloy. The plated-metal-layer of Zn-based alloy includes Zn as main element and a small amount of Al, Mg, or the like, and the metallographic structure thereof includes Zn phase, Al phase, Mg₂Zn phase, or the like. The plated-metal-layer of Al-based alloy includes Al as main element and a small amount of Si, Fe, or the like, and the metallographic structure thereof includes Al phase, Si phase, Fe₂Al₅ phase, or the like.

As the plated steels in which the chemical composition of plated alloy is quite different from that of the conventional surface-treated steel sheets, the present inventors disclosed the steel sheets with the plated layer containing Mg-based alloy in patent documents 5 to 7. Based on the above plated steels, the present inventors have tried to further improve the corrosion resistance by focusing the quasicrystal which has hardly been considered for the improvement of the corrosion resistance of the plated layer (plated-metal-layer).

The present inventors considered a metallographic structure which preferably improve the corrosion resistance particularly by focusing on dispersing quasicrystals having an average equivalent circle diameter of equal to or smaller than 1 μm in the plated-metal-layer. As described above, the quasicrystal is known as the crystal structure which has unique rotational symmetry not to be obtained by general metals and alloys, is a non-periodic crystal structure having fivefold symmetry for example, and is equivalent to a non-periodic structure represented by a three-dimensional Penrose Pattern.

PRIOR ART DOCUMENT Patent Document

[Patent Document 1] Japanese Unexamined Patent Application, First Publication No. 2005-113235

[Patent Document 2] Japanese Unexamined Patent Application, First Publication No. 2008-69438

[Patent Document 3] Japanese Unexamined Patent Application, First Publication No. H-08-176762

[Patent Document 4] Japanese Unexamined Patent Application, First Publication No. 2004-267878

[Patent Document 5] Japanese Unexamined Patent Application, First Publication No. 2008-255464

[Patent Document 6] Japanese Unexamined Patent Application, First Publication No. 2010-248541

[Patent Document 7] Japanese Unexamined Patent Application, First Publication No. 2011-219823

[Patent Document 8] Published Japanese Translation No. 2007-525596 of the PCT International Publication

DISCLOSURE OF THE INVENTION Problems to be Solved by the Invention

An object of the present invention is to provide a plated steel sheet which is rapidly improved in the corrosion resistance requested for applying building materials, automobiles, consumer electronics or the like.

In particular, an object of the present invention is to provide the plated steel sheet having both excellent corrosion resistance and excellent sacrificial protection by focusing the quasicrystal which has hardly been considered for the improvement of the corrosion resistance of the plated layer and by clarifying the morphology of the metallographic structure which maximally improve the corrosion resistance. Specifically, the corrosion resistance and the sacrificial protection of the plated steel sheet is to be improved by clarifying the preferable morphology of the quasicrystal in plated-metal-layer (the plated layer) which has hardly been considered but which is expected to improve the corrosion resistance and by clarifying the processes to preferably form the quasicrystal in the plated-metal-layer.

Means for Solving the Problem

An aspect of the present invention employs the following.

(1) A plated steel sheet with a quasicrystal according to an aspect of the present invention includes a steel sheet and a plated-metal-layer arranged on a surface of the steel sheet,

wherein: the plated-metal-layer includes, as a chemical composition, by atomic %,

28.5% to 52% of Zn,

0.5% to 10% of Al,

0% to 3.5% of Ca,

0% to 3.5% of Y,

0% to 3.5% of La,

0% to 3.5% of Ce,

0% to 0.5% of Si,

0% to 0.5% of Ti,

0% to 0.5% of Cr,

0% to 2% of Fe,

0% to 0.5% of Co,

0% to 0.5% of Ni,

0% to 0.5% of V,

0% to 0.5% of Nb,

0% to 0.5% of Cu,

0% to 0.5% of Sn,

0% to 0.2% of Mn,

0% to 0.5% of Sr,

0% to 0.5% of Sb,

0% to 0.5% of Pb, and

a balance of Mg and impurities;

the plated-metal-layer includes, as a metallographic structure, a quasicrystal phase;

a magnesium content, a zinc content, and an aluminum content expressed in atomic % in the quasicrystal phase satisfy 0.5≦Mg/(Zn+Al)≦0.83; and

an average equivalent circle diameter of the quasicrystal phase is equal to or larger than 0.01 μm and equal to or smaller than 1 μm.

(2) In the plated steel sheet with the quasicrystal according to (1),

a calcium content, an yttrium content, a lanthanum content, and a cerium content expressed in atomic % in the chemical composition of the plated-metal-layer may satisfy

0.3%≦Ca+Y+La+Ce≦3.5%.

(3) In the plated steel sheet with the quasicrystal according to (1) or (2),

a silicon content, a titanium content, and a chromium content expressed in atomic % in the chemical composition of the plated-metal-layer may satisfy

0.005%≦Si+Ti+Cr≦0.5%.

(4) In the plated steel sheet with the quasicrystal according to any one of (1) to (3),

a zinc content and an aluminum content expressed in atomic % in the chemical composition of the plated-metal-layer may satisfy

30%≦Zn+Al≦52%.

(5) In the plated steel sheet with the quasicrystal according to any one of (1) to (4),

when viewed in a cross section, whose cutting direction is parallel to a thickness direction of the plated-metal-layer,

the metallographic structure of the plated-metal-layer may be a bimodal structure which comprises a fine domain composed of a grain having an equivalent circle diameter of 0.2 μm or smaller and a coarse domain composed of a grain having an equivalent circle diameter of larger than 0.2 μm,

the coarse domain may include at least one selected from the quasicrystal phase, a Zn phase, an Al phase and a MgZn phase,

the fine domain may include at least one selected from a Mg₅₁Zn₂₀ phase, a Zn phase, an amorphous phase, a Mg₃₂(Zn,Al)₄₉ phase, and

the average equivalent circle diameter of the quasicrystal phase may be larger than 0.2 μm and equal to or smaller than 1 μm.

(6) In the plated steel sheet with the quasicrystal according to any one of (1) to (4),

when viewed in a cross section, whose cutting direction is parallel to a thickness direction of the plated-metal-layer,

the metallographic structure of the plated-metal-layer may be a bimodal structure which comprises a fine domain composed of a grain having an equivalent circle diameter of 0.2 μm or smaller and a coarse domain composed of a grain having an equivalent circle diameter of larger than 0.2 μm,

the coarse domain may include at least one selected from a Zn phase, an Al phase and a MgZn phase,

the fine domain may include at least one selected from the quasicrystal phase, a Mg₅₁Zn₂₀ phase, a Zn phase, an amorphous phase, a Mg₃₂(Zn,Al)₄₉ phase, and

the average equivalent circle diameter of the quasicrystal phase is equal to or larger than 0.01 μm and equal to or smaller than 0.2 μm.

(7) In the plated steel sheet with the quasicrystal according to any one of (1) to (5),

an area fraction of the coarse domain in the metallographic structure may be equal to or more than 5% and equal to or less than 50%, and

an area fraction of the fine domain in the metallographic structure may be equal to or more than 50% and equal to or less than 95%.

(8) In the plated steel sheet with the quasicrystal according to any one of (1) to (4), and (6),

an area fraction of the coarse domain in the metallographic structure may be equal to or more than 5% and equal to or less than 50%, and

an area fraction of the fine domain in the metallographic structure may be equal to or more than 50% and equal to or less than 95%.

(9) In the plated steel sheet with the quasicrystal according to any one of (1) to (5), and (7),

an area fraction of the quasicrystal phase included in the coarse domain may be equal to or more than 80% and less than 100% in the coarse domain, and

an area fraction in total of the Mg₅₁Zn₂₀ phase, the Zn phase, the amorphous phase, and the Mg₃₂(Zn,Al)₄₉ phase included in the fine domain may be equal to or more than 80% and less than 100% in the fine domain.

(10) In the plated steel sheet with the quasicrystal according to any one of (1) to (4), (6), and (8),

an area fraction in total of the Zn phase, the Al phase, and the MgZn phase included in the coarse domain may be equal to or more than 80% and less than 100% in the coarse domain, and

an area fraction of the quasicrystal phase included in the fine domain may be more than 0% and less than 10% in the fine domain.

(11) In the plated steel sheet with the quasicrystal according to any one of (1) to (5), (7), and (9),

when viewed in the cross section and when a thickness of the plated-metal-layer is regarded as D, an area from a surface of the plated-metal-layer toward the steel sheet in the thickness direction to 0.05×D is regarded as an outermost area of the plated-metal-layer, and an area from an interface between the steel sheet and the plated-metal-layer toward the plated-metal-layer in the thickness direction to 0.05×D is regarded as an innermost area of the plated-metal-layer,

an area fraction of the coarse domain in the outermost area of the plated-metal-layer may be equal to or more than 7% and less than 100% and an area fraction of the coarse domain in the innermost area of the plated-metal-layer may be equal to or more than 7% and less than 100%, and

when an area except for the outermost area and the innermost area of the plated-metal-layer is regarded as a main-body area of the plated-metal-layer,

an area fraction of the fine domain in the main-body area of the plated-metal-layer may be equal to or more than 50% and less than 100%.

(12) In the plated steel sheet with the quasicrystal according to any one of (1) to (4), (6), (8) and (10),

when viewed in the cross section and when a thickness of the plated-metal-layer is regarded as D, an area from a surface of the plated-metal-layer toward the steel sheet in the thickness direction to 0.05×D is regarded as an outermost area of the plated-metal-layer, and an area from an interface between the steel sheet and the plated-metal-layer toward the plated-metal-layer in the thickness direction to 0.05×D is regarded as an innermost area of the plated-metal-layer,

an area fraction of the coarse domain in the outermost area of the plated-metal-layer may be equal to or more than 7% and less than 100% and an area fraction of the coarse domain in the innermost area of the plated-metal-layer may be equal to or more than 7% and less than 100%, and

when an area except for the outermost area and the innermost area of the plated-metal-layer is regarded as a main-body area of the plated-metal-layer,

an area fraction of the fine domain in the main-body area of the plated-metal-layer may be equal to or more than 50% and less than 100%.

(13) In the plated steel sheet with the quasicrystal according to any one of (1) to (12),

a Mg phase may be absent in the metallographic structure of the plated-metal-layer.

(14) The plated steel sheet with the quasicrystal according to any one of (1) to (13) may further include a Fe—Al containing alloy layer,

the Fe—Al containing alloy layer may be arranged between the steel sheet and the plated-metal-layer,

the Fe—Al containing alloy layer may include at least one selected from Fe₅Al₂ and Al_(3.2)Fe, and

a thickness of the Fe—Al containing alloy layer may be equal to or more than 10 nm and equal to or less than 1000 nm.

(15) A method of producing a plated steel sheet with a quasicrystal according to an aspect of the present invention, which is the method of producing the plated steel sheet with the quasicrystal according to any one of (1) to (14), includes:

a hot-dip-plating process of dipping a steel sheet into a hot-dip-plating bath having an adjusted composition in order to form a plated-metal-layer on a surface of the steel sheet;

a first cooling process of cooling the steel sheet after the hot-dip-plating process under conditions such that an average cooling rate of the plated-metal-layer is equal to or faster than 15° C./sec and equal to or slower than 50° C./sec in a temperature range where a temperature of the plated-metal-layer is from T_(melt)+10° C. to T_(solid-liquid), when the T_(melt) in unit of ° C. is regarded as a liquidus temperature of the plated-metal-layer and when the T_(solid-liquid) in unit of ° C. is a temperature range where the plated-metal-layer is in a coexistence state of a solid phase and a liquid phase and where a volume ratio of the solid phase to the plated-metal-layer is equal to or more than 0.01 and equal to or less than 0.1; and

a second cooling process of cooling the steel sheet after the first cooling process under conditions such that an average cooling rate of the plated-metal-layer is equal to or faster than 100° C./sec and equal to or slower than 3000° C./sec in a temperature range where a temperature of the plated-metal-layer is from a temperature at finishing the first cooling process to 250° C.

(16) In the method of producing the plated steel sheet with the quasicrystal according to (15), in the hot-dip-plating process:

an oxygen concentration of an atmosphere at dipping the steel sheet may be 100 ppm or less in volume ratio;

a plating tub to hold the hot-dip-plating bath may be a steel tub;

T_(bath) which is a temperature of the hot-dip-plating bath may be equal to or higher than 10° C. and equal to or lower than 100° C. higher than the T_(melt); and

a time for dipping the steel sheet into the hot-dip-plating bath may be equal to or longer than 1 sec and equal to or shorter than 10 sec.

Effects of the Invention

According to the above aspects of the present invention, it is possible to provide the plated steel sheet which is further excellent in the corrosion resistance requested for applying building materials, automobiles, consumer electronics or the like. Therefore, it is possible to prolong the useful life of the materials as compared with the conventional surface-treated steel sheets.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a SEM micrograph of a plated steel sheet according to an embodiment of the present invention and a metallographic micrograph obtained by observing a cross section whose cutting direction is parallel to a thickness direction of the plated steel sheet.

FIG. 2 is a TEM micrograph of a plated steel sheet according to the embodiment and a metallographic micrograph obtained by observing the cross section whose cutting direction is parallel to the thickness direction of the plated steel sheet.

FIG. 3 is a TEM micrograph of a plated steel sheet according to the embodiment and a metallographic micrograph obtained by observing the cross section whose cutting direction is parallel to the thickness direction of the plated steel sheet.

FIG. 4A is an electron diffraction pattern obtained from a local area 2 a 1 in a coarse domain 2 a shown in FIG. 2.

FIG. 4B is an electron diffraction pattern obtained from a local area 2 b 1 in a fine domain 2 b shown in FIG. 2.

FIG. 5A is an electron diffraction pattern obtained from a local area 2 a 2 in a coarse domain 2 a shown in FIG. 3.

FIG. 5B is an electron diffraction pattern obtained from a local area 2 b 2 in a fine domain 2 b shown in FIG. 3.

FIG. 6 is an equilibrium state diagram of a binary Zn—Mg system.

FIG. 7 is a liquidus surface phase diagram of a ternary Zn—Al—Mg system.

EMBODIMENTS OF THE INVENTION

Hereinafter, a preferable embodiment of the present invention will be described in detail. However, the present invention is not limited only to the configuration which is disclosed in the embodiment, and various modifications are possible without departing from the aspect of the present invention.

The plated steel sheet according to the embodiment includes a steel sheet (base metal) and a plated-metal-layer (plated layer) arranged on a surface of the steel sheet. The plated-metal-layer whose shape is thin film is the alloy which has adhesion to the base metal, equips the steel sheet with a function such as anticorrosion, and does not harm the properties of the base metal such as strength or rigidity. Specifically, the plated steel sheet according to the embodiment is the composite material in which two types of metal-alloy-materials that are the steel sheet and the plated-metal-layer are layered. In an interface between the steel sheet and the plated-metal-layer, an interface alloy layer (Fe—Al containing alloy layer) or a diffused area formed by mutual diffusion of metal atoms may exist as a result of the composition, and thereby, the interface adherence may be increased due to atomic bonding of metal. First, the properties requested to the plated-metal-layer of the plated steel sheet according to the embodiment will be described.

The plated-metal-layer of the plated steel sheet is required to be excellent in anticorrosion performance. The anticorrosion performance is classified into the corrosion resistance and the sacrificial protection. In general, the corrosion resistance of the plated-metal-layer corresponds to the corrosive resistivity of the plated-metal-layer itself, and is usually evaluated by the corrosion loss of the plated-metal-layer after a predetermined time in various corrosion tests.

When the corrosion loss is small, the plated-metal-layer remains for a long time as a protective coat of the steel sheet (base metal), and thus, the corrosion resistance is excellent. When the corrosion loss is evaluated by using pure metals, the corrosion resistance of Zn tends to be better than that of Mg, and the corrosion resistance of Al tends to be better than that of Zn in general.

On the other hand, the sacrificial protection of the plated-metal-layer corresponds to the protective function for the steel sheet in which the plated-metal-layer is preferentially corroded instead of the steel sheet when the steel sheet is accidentally exposed in corrosive environment. When the sacrificial protection is evaluated by using pure metals, the metal which is electrochemically less-noble and which tends to be corroded is excellent in the sacrificial protection. Thus, the sacrificial protection of Zn tends to be better than that of Al, and the sacrificial protection of Mg tends to be better than that of Zn in general.

The steel sheet plated the Zn—Mg alloy according to the embodiment includes a large amount of Mg in the plated-metal-layer, and thus, is excellent in the sacrificial protection. On the other hand, the point to be improved is to reduce the corrosion loss of the plated-metal-layer, which is to improve the corrosion resistance of the plated-metal-layer.

The present inventors have investigated a constituent phase of the metallographic structure of the plated-metal-layer in order to preferably reduce the corrosion loss of the plated-metal-layer in the steel sheet plated the Zn—Mg alloy. As a result, it is found that the corrosion resistance is drastically improved by including the quasicrystal phase in the plated-metal-layer.

The metallographic structure of the plated-metal-layer is the main characteristic of the plated steel sheet according to the embodiment. In a case where the plated steel sheet is produced based on a chemical composition within a specific range, which will be described later, under specific production conditions, a quasicrystal phase is formed in the plated-metal-layer, and corrosion resistance can be significantly improved. In the embodiment, an average equivalent circle diameter (diameter) of the quasicrystal phase formed in the plated-metal-layer is equal to or larger than 0.01 μm and equal to or smaller than 1 μm.

The plated-metal-layer of the plated steel sheet according to the embodiment contains the aforementioned quasicrystal phase. Therefore, the corrosion resistance thereof is further improved compared to the corrosion resistance of a plated-metal-layer not containing a quasicrystal phase. Furthermore, the plated-metal-layer of the plated steel sheet according to the embodiment contains a large amount of Mg. Therefore, the plated-metal-layer also exhibits excellent sacrificial protection with respect to the steel sheet. That is, the plated steel sheet according to the embodiment includes an ideal plated-metal-layer excellent in both of the corrosion resistance and the sacrificial protection.

Hereinafter, regarding the plated steel sheet according to the embodiment, the chemical composition of the plated-metal-layer, the metallographic structure of the plated-metal-layer, and the production conditions will be specifically described in this order.

Generally, when constitutive equations of metallic phases or intermetallic compounds such as Zn, Al, Mg₂Zn, and Fe₂Al₅ are described, an atomic ratio is used instead of a mass ratio. The embodiment will be described using an atomic ratio because the embodiment is focused on a quasicrystal phase. That is, unless otherwise specified, “%” showing a chemical composition in the following description means atomic %.

First, regarding the chemical composition of the plated-metal-layer, the numerical ranges and why the numerical ranges are limited will be described.

The plated-metal-layer of the plated steel sheet according to the embodiment contains Zn and Al as basic components, optional components as necessary, and Mg and impurities as a balance.

Zn (Zinc): 28.5% to 52%

In order to obtain a quasicrystal phase as a metallographic structure of the plated-metal-layer, the plated-metal-layer must contain Zn within the above range. Therefore, a Zn content in the plated-metal-layer is set to be 28.5% to 52%. The Zn content is determined based on a eutectic composition (Mg 72%-Zn 28%) of an equilibrium state diagram of a binary Mg—Zn system shown in FIG. 6, and the Zn content is higher than a Mg—Zn eutectic composition. When a Mg content is higher than the eutectic composition and the Zn content is lower than the eutectic composition, a Mg phase having poor corrosion resistance is mainly formed in the metallographic structure. Consequently, a corrosion resistance of the plated-metal-layer deteriorates. Therefore, the Zn content in the plated-metal-layer is set to be equal to or greater than 28.5%. From this, a Zn phase can be dispersed in the plated-metal-layer as priority, in a proper production condition. A lower limit of the Zn content may be 30% for a formation of the Zn phase in a further higher area fraction. The corrosion resistance is improved when the area fraction of the Zn phase increases. However, when the Zn content is greater than 52%, a composition balance of the plated-metal-layer is lost, intermetallic compounds such as Mg₄Zn₇ and MgZn is formed in a large amount, and the quasicrystal phase is not formed. Consequently, the corrosion resistance deteriorates. Therefore, the upper limit of the Zn content is set to be 52%.

In order to further improve the corrosion resistance by preferably forming the quasicrystal, the Zn content is preferably set to be equal to or greater than 33%. If the Zn content is equal to or greater than 33%, a compositional range is established in which the Zn phase or the quasicrystal phase easily grows as a primary phase, and a Mg phase does not easily grow. That is, an amount (area fraction) of the quasicrystal phase in the plated-metal-layer can be increased, and an amount of the Mg phase deteriorating corrosion resistance can be reduced as much as possible. More preferably, the Zn content is set to be equal to or greater than 35%. Generally, if the plated steel sheet is produced within the above compositional range by the production method according to the embodiment, the Mg phase practically does not exist.

Al (aluminum): 0.5% to 10%

Al is an element improving the corrosion resistance of a planar portion of the plated-metal-layer. Furthermore, Al is an element accelerating the formation of the quasicrystal phase. In order to obtain these effects, an Al content in the plated-metal-layer is set to be equal to or greater than 0.5%. Additionally, when the Al content is equal to or greater than 0.5%, the Zn phase or an Al phase are formed in the plated-metal-layer in addition to the above described quasicrystal phase. The corrosion resistance of the plated-metal-layer is preferably improved by a formation of an eutectic structure of the Zn phase and the Al phase. The corrosion resistance is preferably further improved by an coexistence of a three phase of the amorphous phase, the Zn phase, and the Al phase. However, when the Al content is greater than 10%, a coarsening of a grain size of the Al phase drastically occurs in the plated-metal-layer, and the eutectic structure of the Zn phase and the Al phase is not formed. Additionally, the Zn phase is not formed. Consequently, the corrosion resistance deteriorates. Therefore, an upper limit of the Al content in the plated-metal-layer is set to be 10%. In order to preferably control an average equivalent circle diameter of the quasicrystal phase, the Al content in the plated-metal-layer may be set to be less than 5%. When the average equivalent circle diameter of the quasicrystal phase becomes larger, although the corrosion resistance is not affected, a conversion coating property becomes slightly inferior, a corrosion resistance under coating (a corrosion resistance after coating) is likely to deteriorate. In addition, it is preferable that the element Al is contained in the plated-metal-layer by forming a Fe—Al interface alloy layer which will be described later.

It is preferable that a grain size of the quasicrystal phase in the plated-metal-layer is small, because an occurrence of red rust in a processed portion is suppressed. For example, in a case where the quasicrystal phase in a plated-metal-layer is coarse, the plated-metal-layer is likely to be partially peeled off from a steel sheet originating the quasicrystal phase in the plated-metal-layer, when a high deformation (drawing process, ironing process) or the like is applied to the plated steel sheet. Red rust is likely to occur because the steel sheet is exposed at the peeled portion. In contrast, in a case where the quasicrystal phase in a plated-metal-layer is fine, the plated-metal-layer is not likely to be peeled off from a steel sheet originating the quasicrystal phase. If the plated-metal-layer is peeled off from a steel sheet, the occurrence of red rust at the peeled portion is suppressed because an area of the peeled portion is small. For example, when the corrosion resistance of a cylindrical draw portion of a plated steel sheet which is processed by a cylindrical drawing is evaluated, in a case where the average equivalent circle diameter of the quasicrystal phase is equal to or less than 1 μm, red rust is preferably suppressed.

In order to more preferably form the quasicrystal phase in the plated-metal-layer, it is preferable to control the Zn content and the Al content as below. That is, the Zn content and the Al content, expressed in atomic %, in the chemical composition of the plated-metal-layer preferably satisfy 30%≦Zn+Al≦52%. When the Zn content and the Al content satisfy the above condition, the quasicrystal phase is formed in the plated-metal-layer at a preferred area fraction. It is preferable that the Zn content and the Al content satisfy the above conditions, because then the quasicrystal phase is formed in the plated-metal-layer at an area fraction of 5% to 12% with respect to the total area of the plated-metal-layer. The technical reason is unclear. However, the formation of the quasicrystal phase at the aforementioned area fraction is considered to be related to the facts that the quasicrystal phase in the embodiment has a crystal structure mainly composed of Zn and Mg, the formation of the quasicrystal phase is accelerated by the substitution of Al with Zn, and there is an optimal value of the amount of Al substituted.

Mg (magnesium) is a main element which constitutes the plated-metal-layer similarly to Zn and Al and improves the sacrificial protection. Furthermore, Mg is an important element accelerating the formation of the quasicrystal phase. In the embodiment, a content of Mg in the plated-metal-layer does not need to be particularly specified and is equal to the aforementioned balance minus a content of impurities. That is, the Mg content may be greater than 38% and less than 71%. However, the Mg content in the balance is preferably equal to or greater than 50%, and more preferably equal to or greater than 55%. In the embodiment, although the plated-metal-layer must contain Mg, in order to improve the corrosion resistance, it is preferable to inhibit Mg contained in the plated-metal-layer from being precipitated as a Mg phase in the plated-metal-layer. That is, because the Mg phase deteriorates the corrosion resistance, it is preferable that Mg contained in the plated-metal-layer is in the form of a quasicrystal phase or a constituent of other intermetallic compounds.

The plated-metal-layer of the plated steel sheet according to the embodiment contains impurities in addition to the aforementioned basic components. Herein, the impurities mean elements such as C, N, O, P, S, and Cd that are mixed in from raw materials of steel and plated alloys, the production environment, or the like when the plated steel sheet is industrially produced. Even if these elements are contained as impurities in an amount of about 0.1% respectively, the aforementioned effects are not impaired.

The plated-metal-layer of the plated steel sheet according to the embodiment may further contain, instead of a portion of Mg described above as a balance, at least one or more optional components selected from Ca, Y, La, Ce, Si, Ti, Cr, Fe, Co, Ni, V, Nb, Cu, Sn, Mn, Sr, Sb, and Pb. The plated-metal-layer may contain these optional components according to the purpose. Therefore, the lower limit of the content of these optional components does not need to be limited and may be 0%. Even if these optional components are contained as impurities, the aforementioned effects are not impaired.

Ca (calcium): 0% to 3.5%

Y (yttrium): 0% to 3.5%

La (lanthanum): 0% to 3.5%

Ce (cerium): 0% to 3.5%

In order to improve workability of hot-dip plating, Ca, Y, La, and Ce may be contained in the plated-metal-layer. In a case where the plated steel sheet according to the embodiment is produced, a highly oxidative hot-dip Mg alloy is held in the atmosphere as a plating bath. Therefore, it is preferable to take a certain measure to prevent the oxidation of Mg. Ca, Y, La, and Ce are more easily oxidized compared to Mg and prevent the oxidation of Mg in the bath by forming a stable oxide layer on the surface of the plating bath in a molten state. Accordingly, in the plated-metal-layer, a Ca content may be set to be 0% to 3.5%, a Y content may be set to be 0% to 3.5%, a La content may be set to be 0% to 3.5%, and a Ce content may be set to be 0% to 3.5%. More preferably, the lower limit and the upper limit of each of the Ca content, the Y content, the La content, and the Ce content may be set to be 0.3% and 2.0% respectively.

It is preferable that the plated-metal-layer contain at least one element selected from Ca, Y, La, and Ce in an amount of equal to or greater than 0.3% in total, because then the plating bath with a high Mg content can be held in the atmosphere without being oxidized. In contrast, Ca, Y, La, and Ce are easily oxidized and negatively affect the corrosion resistance in some cases. Therefore, the upper limit of the total content of Ca, Y, La, and Ce is preferably set to be 3.5%. That is, it is preferable that the Ca content, the Y content, the La content, and the Ce content, expressed in atomic %, in the chemical composition of the plated-metal-layer satisfy 0.3%≦Ca+Y+La+Ce≦3.5%.

In order to preferably generate the quasicrystal phase in the plated-metal-layer, it is preferable that the total content of Ca, Y, La, and Ce is set to be equal to or greater than 0.3% and equal to or less than 2.0%. Although these elements are considered to be substituted with Mg constituting the quasicrystal phase, in a case where the plated-metal-layer contains a large amount of these elements, the formation of the quasicrystal phase is hindered in some cases. If the plated-metal-layer contains these elements in an appropriate amount, the effect of suppressing red rust of the quasicrystal phase is improved. Presumably, this effect may result from a fact that the elution timing of the quasicrystal phase affects retentivity of white rust. That is, presumably, after the quasicrystal phase in the plated-metal-layer is eluted, the aforementioned elements may be incorporated into the formed white rust, and accordingly, the rustproofness of white rust is improved, and it takes a long time until red rust occurs due to the corrosion of the base metal.

The obtained effects (antioxidation and the formation of the quasicrystal phase) described above become relatively strong when the plated-metal-layer contains Ca, La, Ce among the aforementioned elements. In contrast, it was revealed that the aforementioned effects brought about when the plated-metal-layer contains Y is weaker than the effects brought about when the plated-metal-layer contain Ca, La, and Ce. Presumably, this may be related to the fact that Ca, La, and Ce are elements that are more easily oxidized and have higher reactivity compared to Y. When the chemical composition of the quasicrystal phase is analyzed through Energy Dispersive X-ray Spectroscopy (EDX), Y is not detected in many cases. Therefore, Y is presumed not to be easily incorporated into the quasicrystal. In contrast, Ca, La, and Ce tend to be detected from the quasicrystal phase at a high concentration compared to the concentration thereof contained in the plated-metal-layer. That is, the plated-metal-layer does not necessarily contain Y. In a case where the plated-metal-layer does not contain Y, 0.3%≦Ca+La+Ce≦3.5% or 0.3%≦Ca+La+Ce≦2.0% may be satisfied.

In a case where the atmosphere contacting the plating bath is purged with an inert gas (for example, Ar) or evacuated, that is, in a case where an oxygen blocking device is installed in the production facilities, Ca, Y, La, and Ce are not necessarily added.

The total content of Al, Ca, La, Y, and Ce is preferably controlled as below. That is, the Al content, the Ca content, the La content, the Y content, and the Ce content, expressed in atomic %, in the chemical composition of the plated-metal-layer preferably satisfy 0.5%≦Al+Ca+La+Y+Ce<6%, and more preferably satisfy 0.5%≦Al+Ca+La+Y+Ce<5.5%. If the total content of Al, Ca, La, Y, and Ce satisfies the aforementioned conditions, a quasicrystal phase having a preferred average equivalent circle diameter is formed in the plated-metal-layer. If the aforementioned conditions are satisfied, the average equivalent circle diameter of the quasicrystal phase can be controlled and become equal to or smaller than 0.6 μm. Furthermore, it is possible to improve powdering properties (peeling resistance against a compressive stress) of the plated layer. Presumably, Ca, La, Y, Ce, or the like added in a trace amount in addition to Al may be precipitated in the grain boundary of the quasicrystal phase, and hence the grain boundary may be strengthened.

Si (silicon): 0% to 0.5%

Ti (titanium): 0% to 0.5%

Cr (chromium): 0% to 0.5%

The plated-metal-layer may contain Si, Ti, and Cr, as necessary, such that the quasicrystal phase is preferably formed. If the plated-metal-layer contains Si, Ti, and Cr in a trace amount, the quasicrystal phase is easily formed or the structure of the quasicrystal phase is stabilized. It is considered that Si may become an origin (nuclear) of the formation of the quasicrystal phase by means of forming fine Mg₂Si by being bonded to Mg, and Ti and Cr, which exhibit poor reactivity with respect to Mg, may become the origin of the formation of the quasicrystal phase by means of forming a fine metallic phase. Furthermore, generally, the formation of the quasicrystal phase is affected by a cooling rate at the time of production. If the plated-metal-layer contains Si, Ti, and Cr, the cooling rate tends to become less dependent on the formation of the quasicrystal phase. Therefore, in the plated-metal-layer, a Si content may be set to be 0% to 0.5%, a Ti content may be set to be 0% to 0.5%, and a Cr content may be set to be 0% to 0.5%. More preferably, the lower limit and the upper limit of each of the Si content, the Ti content, and the Cr content may be set to be 0.005% and 0.1% respectively.

It is preferable that the plated-metal-layer contains at least one element selected from Si. Ti, and Cr in an amount of 0.005% to 0.5% in total, because then the structure of the quasicrystal is further stabilized. That is, the Si content, the Ti content, and the Cr content, expressed in atomic %, in the chemical composition of the plated-metal-layer preferably satisfy 0.005%≦Si+Ti+Cr≦0.5%. Furthermore, if these elements are contained in an appropriate amount, the quasicrystal is preferably formed finely and in a large amount, and the corrosion resistance of the surface of the plated-metal-layer is improved. In addition, the corrosion resistance in a humid environment is improved, and the occurrence of white rust is inhibited.

Co (cobalt): 0% to 0.5%

Ni (nickel): 0% to 0.5%

V (vanadium): 0% to 0.5%

Nb (niobium): 0% to 0.5%

Co, Ni, V, and Nb have the same effects as those of Si, Ti, and Cr described above. In order to obtain the aforementioned effects, a Co content may be set to be 0% to 0.5%, a Ni content may be set to be 0% to 0.5%, a V content may be set to be 0% to 0.5%, and a Nb content may be set to be 0% to 0.5%. More preferably, the lower limit and the upper limit of each of the Co content, the Ni content, the V content, and the Nb content may be set to be 0.05% and 0.1% respectively. Here, the corrosion resistance improving effects of these elements are weaker than that of Si, Ti, and Cr.

In some cases, the elements constituting a steel sheet, which is a base metal, are mixed into the plated-metal-layer from the steel sheet. Particularly, during hot-dip plating, due to the mutual diffusion of elements in which the elements are diffused from the steel sheet to the plated-metal-layer and from the plated-metal-layer to the steel sheet, the adherence is improved. Therefore, the plated-metal-layer contains a certain amount of Fe (iron) in some cases. For example, Fe is contained in an amount of around 2% in the entire chemical composition of the plated-metal-layer in some cases. However, Fe diffused to the plated-metal-layer frequently forms an intermetallic compound by reacting with Al and Zn in the vicinity of the interface between the steel sheet and the plated-metal-layer. Therefore, Fe is less likely to affect the corrosion resistance of the plated-metal-layer. Consequently, an Fe content in the plated-metal-layer may be set to be 0% to 2%. Similarly, the elements constituting the steel sheet that have been diffused to the plated-metal-layer (elements other than the elements described above in the embodiment that have been diffused to the plated-metal-layer from the steel sheet) are less likely to affect the corrosion resistance of the plated-metal-layer.

Cu (copper): 0% to 0.5%

Sn (tin): 0% to 0.5%

In order to improve the adherence between the steel sheet and the plated-metal-layer, the steel sheet having not yet been subjected to a hot-dip plating process is preliminarily plated with Ni, Cu, Sn, or the like in some cases. In a case where the plated steel sheet is produced using the preliminarily plated steel sheet, the plated-metal-layer contains the aforementioned elements approximately in an amount of up to 0.5% in some cases. Among Ni, Cu, and Sn, Cu and Sn do not have the aforementioned effects that Ni has. However, even if Cu and Sn are contained in an amount of about 0.5% in the plated-metal-layer, they are less likely to affect the quasicrystal formation behavior or the corrosion resistance of the plated-metal-layer. Therefore, in the plated-metal-layer, a Cu content may be set to be 0% to 0.5%, and a Sn content may be set to be 0% to 0.5%. More preferably, the lower limit and the upper limit of each of the Cu content and the Sn content may be set to be 0.005% and 0.4% respectively.

Mn (manganese): 0% to 0.2%

In recent years, as a steel sheet which is a base metal of a plated steel sheet, high tensile strength steel (high strength steel) has been used. In a case where a plated steel sheet is produced using the high tensile strength steel, the elements such as Si and Mn contained in the high tensile strength steel are diffused in the plated-metal-layer in some cases. Between Si and Mn, Mn does not have the aforementioned effects that Si has. However, even if the Mn is contained in an amount of about 0.2% in the plated-metal-layer, the elements is not likely to affect the quasicrystal formation behavior or the corrosion resistance of the plated-metal-layer. Therefore, a Mn content in the plated-metal-layer may be set to be 0% to 0.2%. More preferably, the lower limit and the upper limit of the Mn content may be set to be 0.005% and 0.1% respectively.

Sr (strontium): 0% to 0.5%

Sb (antimony): 0% to 0.5%

Pb (lead): 0% to 0.5%

Sr, Sb, and Pb are elements improving the appearance of plating and effective for improving antiglare properties. In order to obtain the effect, in the plated-metal-layer, a Sr content may be set to be 0% to 0.5%, a Sb content may be set to be 0% to 0.5%, and a Pb content may be set to be 0% to 0.5%. In a case where the Sr content, the Sb content, and the Pb content are within the above range, the elements practically do not affect the corrosion resistance. More preferably, the lower limit and the upper limit of each of the Sr content, the Sb content, and the Pb content may be set to be 0.005% and 0.4% respectively.

The aforementioned chemical composition of the plated-metal-layer is measured using Inductively Coupled Plasma Atomic Emission Spectrometry (ICP-AES), Inductively Coupled Plasma Mass Spectrometry (ICP-MS), or the like. The plated steel sheet is dipped in 10% hydrochloric acid, to which an inhibitor added, for about 1 minute such that the plated-metal-layer portion is peeled off, thereby preparing a solution in which the plated-metal-layer is dissolved. By analyzing the solution through ICP-AES, ICP-MS, or the like, the average chemical composition of the whole plated-metal-layer is obtained.

During the hot-dip plating, a plated-metal-layer having substantially the same chemical composition as the chemical composition of the hot-dip plating bath is formed. Therefore, regarding the elements that undergo mutual diffusion between the steel sheet and the plated-metal-layer to a negligible extent, the chemical composition of the plating bath may be measured, and the measured value may be adopted as the chemical composition of the plated-metal-layer. From the plating bath, a small ingot is collected, drill dust is then collected, and a solution obtained by dissolving the drill dust in an acid is prepared. By analyzing the solution through ICP or the like, the chemical composition of the plating bath is obtained. The measured value of the chemical composition of the plating bath may be used as the chemical composition of the plated-metal-layer.

Next, the metallographic structure of the plated-metal-layer will be described.

The plated-metal-layer of the plated steel sheet according to the embodiment contains a quasicrystal phase as a metallographic structure. The quasicrystal phase is defined as a quasicrystal phase in which the contents of Mg, Zn, and Al, expressed in atomic %, contained in the quasicrystal phase satisfy 0.5≦Mg/(Zn+Al)≦0.83. That is, the quasicrystal phase is defined as a quasicrystal phase in which Mg:(Zn+Al), a ratio of the number of Mg atoms to the total number of Zn atoms and Al atoms, is 3:6 to 5:6. Theoretically, the ratio of Mg:(Zn+Al) is considered to be 4:6. The chemical composition of the quasicrystal phase is preferably calculated by quantitative analysis based on Transmission Electron Microscope-Energy Dispersive X-ray Spectroscopy (TEM-EDX) or by quantitative analysis based on Electron Probe Micro-Analyzer (EPMA) mapping. It is not easy to define the quasicrystal by using an accurate chemical formula just as an intermetallic compound. This is because a repeating lattice unit of the quasicrystal phase cannot be defined unlike a unit lattice of a crystal, and it is difficult to identify the atomic position of Zn and Mg.

In the embodiment, an average equivalent circle diameter of the quasicrystal phase contained in the plated-metal-layer is equal to or larger than 0.01 μm and equal to or smaller than 1 μm. As the quasicrystal phase, by a micrograph and an electron diffraction pattern obtained by TEM, the quasicrystal phase having an average equivalent circle diameter of about 0.01 μm or larger can be identified. It is considered that the plated-metal-layer may include the quasicrystal phase having an equivalent circle diameter of less than 0.01 μm, from the above described reason, a lower limit of the equivalent circle diameter of the quasicrystal phase is set to be 0.01 μm. Additionally, an upper limit of the equivalent circle diameter of the quasicrystal phase is not particularly limited, according to a metallographic structure of the plated-metal-layer which is described below, it is preferable that the upper limit of the equivalent circle diameter of the quasicrystal phase is set to be 1 μm. For further improving the corrosion resistance under coating (the corrosion resistance after coating), it is preferable that the upper limit of the equivalent circle diameter of the quasicrystal phase is set to be 0.8 μm, and it is more preferable that the upper limit of the equivalent circle diameter of the quasicrystal phase is set to be 0.6 μm. In addition, for further improving the corrosion resistance after an ironing process is applied, it is preferable that the upper limit of the average equivalent circle diameter of the quasicrystal phase is set to be 0.5 μm, and it is more preferable that the upper limit of the equivalent circle diameter of the quasicrystal phase is set to be 0.4 μm.

It is preferable that in a case where a cross section whose cutting direction is parallel to a thickness direction of the plated-metal-layer is viewed, the metallographic structure of the plated-metal-layer is a bimodal structure which consists of a coarse domain composed of a grain having an equivalent circle diameter of larger than 0.2 μm and a fine domain composed of a grain having an equivalent circle diameter 0.2 μm or smaller. An upper limit of the equivalent circle diameter of the grain included in the coarse domain and a lower limit of the equivalent circle diameter of the grain included in the fine domain are not particularly limited. However, when the coarse domain becomes larger too much, the dispersion of the metallographic structure becomes uniformly. Therefore, the upper limit of the equivalent circle diameter of the grain included in the coarse domain may be set to be 10 μm, 5 μm, 2 μm, or 1 μm. Additionally, the lower limit of the fine domain may be more than 0 μm or 0.01 μm as necessary.

When the average equivalent circle diameter of the quasicrystal phase is larger than 0.2 μm and equal to or less than 1 μm, in the above described bimodal structure, it is preferable that the coarse domain includes at least one or more kinds of phase selected from the quasicrystal phase, the Zn phase, the Al phase, and the MgZn phase, and the fine domain includes at least one or more kinds of phase selected from a Mg₅₁Zn₂₀ phase, the Zn phase, the amorphous phase, and a Mg₃₂(Zn,Al)₄₉ phase.

When the average equivalent circle diameter of the quasicrystal phase is equal to or larger than 0.01 μm and equal to or less than 0.2 μm, in the above described bimodal structure, it is preferable that the coarse domain includes at least one or more kinds of phase selected from the Zn phase, the Al phase, and the MgZn phase, and the fine domain includes at least one or more kinds of phase selected from the quasicrystal phase, a Mg₅₁Zn₂₀ phase, the Zn phase, the amorphous phase, and a Mg₃₂(Zn,Al)₄₉ phase.

The Zn phase and the Al phase included in the plated-metal-layer may form an eutectic structure. In a case where the Zn phase and the Al phase form an eutectic structure, it is preferable that the average equivalent circle diameter of a block size of the eutectic structure is larger than 0.2 μm.

If the metallographic structure of the plated-metal-layer is controlled to become a bimodal structure consisting of the coarse domain and the fine domain as described above, the corrosion resistance is preferably improved.

Generally, a bimodal structure means a structure in which a frequency distribution such as the equivalent circle diameter of the grain included in the metallographic structure becomes double-peak distribution. In the plated steel sheet according to the embodiment, it is preferable that the frequency distribution of the equivalent circle diameter of the grain included in the metallographic structure of the plated-metal-layer is a double-peak distribution. Here, in the plated steel sheet according to the embodiment, the frequency distribution is not necessarily a double-peak distribution, and the aforementioned effects are obtained even if the frequency distribution is a broad distribution. That is, in the embodiment, the bimodal structure means that the frequency distribution of the equivalent circle diameter of the grain included in the metallographic structure of the plated-metal-layer is not a normal distribution, and the metallographic structure of the plated-metal-layer consists of the fine domain composed of a grain having an equivalent circle diameter of 0.2 μm or smaller and the coarse domain composed of a grain having an equivalent circle diameter of larger than 0.2 μm.

As described above, the average equivalent circle diameter of the quasicrystal phase contained in the metallographic structure of the plated-metal-layer of the plated steel sheet according to the embodiment is equal to or larger than 0.01 μm and equal to or smaller than 1 μm. That is, in a case where each grain of the quasicrystal phase is separately considered, a quasicrystal phase having an equivalent circle diameter of equal to or smaller than 0.2 μm and a quasicrystal phase having an equivalent circle diameter of larger than 0.2 μm are contained in the metallographic structure of the plated-metal-layer. Here, in a case where the average equivalent circle diameter of the quasicrystal phase is larger than 0.2 μm and equal to or smaller than 1 μm, the quasicrystal phase is mainly included in the coarse domain of the plated-metal-layer. Additionally, in a case where the average equivalent circle diameter of the quasicrystal phase is equal to or larger than 0.01 μm and equal to or smaller than 0.2 μm, the quasicrystal phase is mainly included in the fine domain of the plated-metal-layer.

The average equivalent circle diameter of a constituent phase included in the coarse domain, for example, the Al phase, the Zn phase, or the like, is preferably set to be larger than 0.2 μm. In this case, grains of the aforementioned phases having an equivalent circle diameter of equal to or smaller than 0.2 μm and grains of the aforementioned phases having an equivalent circle diameter of larger than 0.2 μm are included in the metallographic structure of the plated-metal-layer. The aforementioned grains are mainly included in the coarse domain. Additionally, in a case where the Al phase and the Zn phase form the eutectic structure, it is preferable that an average equivalent circle diameter of a block size of the eutectic structure is larger than 0.2 μm. In this case, a block having an equivalent circle diameter of equal to or smaller than 0.2 μm and a block having an equivalent circle diameter of larger than 0.2 μm are included in the metallographic structure of the plated-metal-layer. The eutectic structure of the Zn phase and the Al phase is mainly included in the coarse domain. An upper limit of the average equivalent circle diameter of the constituent phase or the eutectic structure included in the coarse domain is not particularly limited. The upper limit may be set to be 10 μm, 5 μm, 2 μm, or 1 μm as necessary.

The average equivalent circle diameter of a constituent phase included in the fine domain, for example, the Mg₅₁Zn₂₀ phase, the amorphous phase, the Mg₃₂(Zn,Al)₄₉ phase or the like, is preferably set to be 0.01 μm to 0.2 μm. In this case, grains of the aforementioned phases having an equivalent circle diameter of equal to or smaller than 0.2 μm and grains of the aforementioned phases having an equivalent circle diameter of larger than 0.2 μm are included in the metallographic structure of the plated-metal-layer. The aforementioned grains are mainly included in the fine domain.

The average equivalent circle diameter of the Zn phase included in the metallographic structure is not particularly limited. The upper limit may be set to be 10 μm, 5 μm, 2 μm, or 1 μm as necessary. The lower limit may be set to be more than 0 μm or 0.01 μm as necessary. That is, the Zn phase may be mainly included in the coarse domain, or the Zn phase may be mainly included in the fine domain.

FIG. 1 is an electron micrograph of a plated steel sheet according to the embodiment, which is a metallographic micrograph obtained by observing a cross section whose cutting direction is parallel to a thickness direction of the plated steel sheet. This cross-sectional image is a backscattered electron compositional image (COMPO image) obtained by observation using a Scanning Electron Microscope (SEM). In FIG. 1, 1 indicates a steel sheet, and 2 indicates a plated-metal-layer. Furthermore, in FIG. 1, 2 a indicates a coarse domain, and 2 b indicates a fine domain. At least one or more kinds of phase among the quasicrystal phase, the Zn phase, the Al phase, and the MgZn phase are included in the coarse domain 2 a, and at least one or more kinds of phase among the quasicrystal phase, the Mg₅₁Zn₂₀ phase, the Zn phase, the amorphous phase, and the Mg₃₂(Zn,Al)₄₉ phase are included in the fine domain 2 b. FIG. 1 shows that the metallographic structure of the plated-metal-layer is a bimodal structure.

In a strict sense, fine intermetallic compounds or metal phases having an equivalent circle diameter of 0.2 μm or smaller are diffused in the coarse domain 2 a in some cases. However, fine grains present in the coarse domain 2 a are not regarded as being the fine domain 2 b. In the embodiment, the fine domain 2 b refers to a domain in which a plurality of fine grains having an equivalent circle diameter 0.2 μm or smaller is continuously piled up and which is found to be an equivalent area when being observed at an SEM level.

FIGS. 2 and 3 are electron micrographs of the plated-metal-layer of the plated steel sheet according to the same embodiment, which is a metallographic micrograph obtained by observing the cross section whose cutting direction is parallel to the thickness direction of the plated steel sheet. This cross-sectional image is obtained by observation using TEM and is a bright field image. FIG. 2 is a metallographic micrograph of a vicinity of a surface of the plated-metal-layer, and FIG. 3 is a metallographic micrograph of a vicinity of an interface between the plated-metal-layer and the steel sheet. In FIGS. 2 and 3, 2 a indicates a coarse domain, and 2 b indicates a fine domain. Similarly to FIG. 1, FIGS. 2 and 3 show that the metallographic structure of the plated-metal-layer is a bimodal structure.

FIG. 4A is an electron diffraction pattern obtained from a local area 2 a 1 in the coarse domain 2 a shown in FIG. 2. FIG. 4B is an electron diffraction pattern obtained from a local area 2 b 1 in the fine domain 2 b shown in FIG. 2. FIG. 4A shows an electron diffraction pattern of a radial regular decagon resulting from an icosahedron structure. The electron diffraction pattern shown in FIG. 4A is obtained from only a quasicrystal and cannot be obtained from any other crystal structures. From the electron diffraction pattern shown in FIG. 4A, it can be confirmed that the quasicrystal phase is included in the coarse domain 2 a. FIG. 4B shows an electron diffraction pattern resulting from the Mg₅₁Zn₂₀ phase. From the electron diffraction pattern shown in FIG. 4B, it can be confirmed that the Mg₅₁Zn₂₀ phase is included in the fine domain 2 b.

FIG. 5A is an electron diffraction pattern obtained from a local area 2 a 2 in the coarse domain 2 a shown in FIG. 3. FIG. 5B is an electron diffraction pattern obtained from a local area 2 b 2 in the fine domain 2 b shown in FIG. 3. From the electron diffraction pattern shown in FIG. 5A, it can be confirmed that the MgZn phase is included in the coarse domain 2 a. From the electron diffraction pattern shown in FIG. 5B, it can be confirmed that the Zn phase is included in the fine domain 2 b. Furthermore, it was confirmed that the Zn phase or the Al phase or the like are included in the coarse domain 2 a and the quasicrystal phase, the amorphous phase and the Mg₃₂(Zn,Al)₄₉ phase are included in the fine domain 2 b in some cases, although such cases are not shown in the drawing.

Here, the quasicrystal which has the average equivalent circle diameter of equal to or less than 1 μm is very fine, and hence the diffraction patterns obtained from multiple quasicrystals may be superposed according to an irradiation position of an electron beam. In this case, a clear electron diffraction pattern of a radial regular decagon may not be obtained, and a diffraction pattern that is similar to a halo pattern peculiar to the amorphous phase. Therefore, it should be needed to take care to identify the quasicrystal phase.

In the fine domain 2 b, a large amount of Mg₅₁Zn₂₀ is observed in a case where the Mg content is high, and a large amount of Mg₃₂(Zn,Al)₄₉ phase is observed in a case where the Mg content is low. The presence of intermetallic compounds or metal phases such as the Zn phase, the Al phase, the MgZn phase, the Mg₅₁Zn₂₀ phase, the Mg₃₂(Zn,Al)₄₉ phase, and the amorphous phase, or the like, can be confirmed using an electron diffraction pattern obtained by TEM as descried above or confirmed using an X-Ray Diffractometer (XRD).

The Mg₅₁Zn₂₀ phase is defined as a constituent phase which can be identified by a JCPDS card: PDF#00-008-0269, #00-065-4290, or a non-patent document “Journal of solid state chemistry 36, 225-233 (1981), Yamato et al.” Furthermore, the Mg₃₂(Zn,Al)₄₉ phase is defined as a constituent phase which can be identified by JCPDS card: PDF#00-019-0029 or #00-039-0951.

The chemical composition of the aforementioned intermetallic compounds or metallic phases can be quantitatively analyzed in a simple manner through TEM-EDX or EPMA. From the result of the quantitative analysis, whether each grain in a constituent phase is one of the quasicrystal phase, the Mg₅₁Zn₂₀ phase, the Mg₃₂(Zn,Al)₄₉ phase, the Mg₄Zn₇ phase, the MgZn phase, the Mg phase, and the Zn phase or other phases can be identified in a simple manner.

The non-patent document “Journal of solid state chemistry 36, 225-233 (1981), Yamato et al.” reports that Mg₅₁Zn₂₀ has a unit lattice close to a cubical crystal and has an atomic structure in which an icosahedron is formed in the unit lattice. The unit lattice of Mg₅₁Zn₂₀ is different from the icosahedron structure of the quasicrystal, and accordingly, in a strict sense, Mg₅₁Zn₂₀ is a phase different from the quasicrystal. However, it is considered that, because the crystal structure of Mg₅₁Zn₂₀ is similar to that of the quasicrystal, the Mg₅₁Zn₂₀ phase may affect the formation of the quasicrystal phase. Mg₃₂(Zn,Al)₄₉ is also called a Frank-Kasper phase and has a complicated atomic configuration (rhombic triacontahedron). Presumably, the Mg₃₂(Zn,Al)₄₉ phase may also be closely related to the formation of the quasicrystal phase similarly to the Mg₅₁Zn₂₀ phase.

The amorphous phase, the quasicrystal phase, and the Mg₅₁Zn₂₀ phase included in the fine domain 2 b in some cases are different in an atomic arrangement (crystal structure), however, there is almost no difference in these phases in regard to a chemical composition represented by a ratio between Zn and Mg. It was confirmed that there is almost no difference in the chemical compositions of the quasicrystal phase, the Mg₅₁Zn₂₀ phase, and the amorphous phase through TEM-EDX mapping of the fine domain 2 b, although it is not shown in the drawing. It is determined that the quasicrystal phase, the Mg₅₁Zn₂₀ phase, and the amorphous phase are non-equilibrium phases which is formed by an accelerated cooling before an equilibrium phase is precipitated, in a production of a plated steel sheet.

The corrosion resistance of the constituent phases of the plated-metal-layer tends to be excellent in order of the quasicrystal phase>the Mg₃₂(Zn,Al)₄₉ phase>the Mg₅₁Zn₂₀ phase>the MgZn phase>the Al phase>the Zn phase>the amorphous phase>>the Mg phase. In a case where these constituent phase are mixed together, increasing a fraction of the phase having high corrosion resistance and uniformly dispersing the phase favors the corrosion resistance of the plated-metal-layer.

Here, in a case where various metallic phases or intermetallic compounds coexist in the plated-metal-layer, due to the formation of a coupling cell, the corrosion resistance further deteriorates than in a case where a single phase exists in the plated-metal-layer. Generally, if a plurality of phases is mixed into the plated-metal-layer, portions that are noble and less noble in terms of electric energy formed in the plated-metal-layer, and hence a coupling cell reaction occurs. The less noble portions corrode first, and hence the corrosion resistance deteriorates. Here, in the plated steel sheet according to the embodiment, in a case where the plated-metal-layer has the aforementioned bimodal structure, the deterioration of corrosion resistance resulting from the formation of the coupling cell is practically not observed and negligible, and rather, the corrosion resistance is markedly improved because the plated-metal-layer contains the quasicrystal.

Furthermore, the average equivalent circle diameter of each of the constituent phase included in the coarse domain may be set to be equal to or less than 2 μm, preferably it may be set to be equal to or less than 1 μm. In this case, for example, an existing Zn-based conversion coating can be applied. In a Zn-based phosphate treatment which is used as a paint undercoat treatment of a metal, generally, when the grain size of the constituent phases included in the coarse domain is increased, a phosphoric acid crystal is less likely to grow on the coarse domain. Then, this domain becomes a lack of hiding (a domain where a conversion crystal is not formed, because a conversion coating property is poor), and the corrosion resistance after coating may deteriorate significantly. In contrast, when the average equivalent circle diameter of each of the constituent phase included in the coarse domain is set to be equal to or less than 2 μm, preferably it is set to be equal to or less than 1 μm, a phosphoric acid crystal can preferably grow.

Generally, an intermetallic compound phase or the amorphous phase have poor plastic deformation properties. If a fraction of a coarse constituent phase having poor plastic workability is reduced, only fine cracks occur in the plated-metal-layer at the time of processing the plated steel sheet. Accordingly, an exposed area of the steel sheet (base metal) is reduced, and the corrosion resistance is preferably improved. Furthermore, because the peeling of the plated-metal-layer is inhibited, it takes a long time until red rust occurs in the processed portion, and hence the corrosion resistance is preferably improved.

The quasicrystal phase is a non-equilibrium phase and thermally unstable. Therefore, if exposed to a high temperature environment with a temperature of around 250° C. to 330° C. for a long period of time, the quasicrystal phase undergoes phase decomposition, and hence the Mg phase having poor corrosion resistance is formed in addition to the Mg₅₁Zn₂₀ phase in some cases. Consequently, the corrosion resistance as the overall plated steel sheet is likely to deteriorate. Care is required in a case where the plated steel sheet is used in a high temperature environment.

As described above, the Zn phase and the Al phase may form the eutectic structure. In the embodiment, the Zn phase is a phase containing more than 95% of Zn, an element such as Mg, Al, and Ca constituting the plated-metal-layer is dissolved in the Zn phase less than 5%. Furthermore, the Al phase is a phase containing more than 33% of Al, Zn is mainly contained in the Al phase in addition to Al, and a small amount of an element constituting the plated-metal-layer, such as Mg or Ca is dissolved in the Al phase. Further, the eutectic structure of the Zn phase and the Al phase (Zn—Al eutectic) refers to an eutectic structure constituted with mixed phase of the aforementioned Zn phase and the aforementioned Al phase.

In the plated-metal-layer of the plated steel sheet according to the embodiment, an area fraction of the coarse domain in the metallographic structure of the entirety of the plated-metal-layer (area of coarse domain/area of plated-metal-layer) is preferably 5% to 50%, and an area fraction of the fine domain in the metallographic structure of the entirety of the plated-metal-layer (area of fine domain/area of plated-metal-layer) is preferably 50% to 95%. If the above conditions are satisfied, the corrosion resistance of the plated-metal-layer is further improved. More preferably, an area fraction of the coarse domain in the metallographic structure of the entirety of the plated-metal-layer may be 5% to 20%, and an area fraction of the coarse domain may be 5% to 10%.

In the plated-metal-layer of the plated steel sheet according to the embodiment, in a case where the average equivalent circle diameter is larger than 2 μm and equal to or smaller than 1 μm, an area fraction of the quasicrystal phase included in the coarse domain is preferably 80% to less than 100% as compared with the coarse domain (area of quasicrystal phase in coarse domain/area of coarse domain), and an area fraction in total of the Mg₅₁Zn₂₀ phase, the Zn phase, the amorphous phase, and the Mg₃₂(Zn,Al)₄₉ phase included in the fine domain is preferably 80% to less than 100% as compared with the fine domain (total area of respective constituent phases in fine domain/area of fine domain). In contrast, in a case where the average equivalent circle diameter is equal to or larger than 0.01 μm and equal to or smaller than 0.2 μm, an area fraction in total of the Zn phase, the Al phase, and the MgZn phase included in the coarse domain is preferably 80% to less than 100% as compared with the coarse domain (area of quasicrystal phase in coarse domain/area of coarse domain), and an area fraction of the quasicrystal phase included in the fine domain is preferably more than 0% to less than 10% as compared with the fine domain (total area of respective constituent phases in fine domain/area of fine domain). When the above conditions are satisfied, the corrosion resistance of the plated-metal-layer is further improved. The balance of the coarse domain and the balance of the fine domain include an intermetallic compound or a metallic phase other than the above in some cases, but even in these cases, the effects of the embodiment are not impaired.

It is preferable that the metallographic structure of the plated-metal-layer in the plated steel sheet according to the embodiment does not contain the Mg phase. The Mg phase contained in the plated-metal-layer deteriorates the corrosion resistance in both the coarse domain and the fine domain. Therefore, it is preferable to suppress the precipitation of the Mg phase as much as possible. Whether or not the Mg phase exists may be determined and confirmed through TEM-EDX, SEM-EDX, XRD, or the like. For example, in a case where a diffraction intensity from a (110) surface of the Mg phase is equal to or less than 1% of a diffraction intensity at a diffraction angle (2θ=36.496°) of the Mg₅₁Zn₂₀ phase (or Mg₇Zn₃ phase) in an XRD diffraction pattern, it can be said that the metallographic structure of the plated-metal-layer does not contain the Mg phase. Likewise, in a case where a number fraction of grains of the Mg phase is equal to or less than 3% when 100 or more grains are randomly sampled in a TEM diffraction pattern, it can be said that the metallographic structure of the plated-metal-layer does not contain the Mg phase. The number fraction of grains of the Mg phase is more preferably less than 2%, and most preferably less than 1%.

In the plated-metal-layer, the Mg phase is easily formed as a primary phase at a temperature immediately below the melting point. Whether the Mg phase will be formed as a primary phase generally depends on the chemical composition of the plated-metal-layer and the production conditions. In a case where the Mg content is higher than in a eutectic composition (Mg 72%-Zn 28%) of an equilibrium state diagram of a binary Mg—Zn system, the Mg phase is likely to be crystallized as a primary phase. In contrast, in a case where the Mg content is lower than the above, in principle, the Mg phase is less likely to be crystallized as a primary phase. The production process according to the embodiment is a process for forming a quasicrystal as a primary phase. Therefore, if the Mg content is higher than in the eutectic composition, it is extremely difficult for the Mg phase to be formed, and even if the formation of the Mg phase could be confirmed, the Mg phase is less likely to present as a main phase. The grain of the Mg phase is present at a number fraction of about up to 3%. The present inventors confirmed that when the Zn content is 28.5% or greater, a proportion of the grain of the Mg phase in grains contained in the metallographic structure of the plated-metal-layer tends to be less than 2% in terms of a number fraction. Furthermore, when the Zn content is 33% or greater, a proportion of the grain of the Mg phase in the grains contained in the metallographic structure of the plated-metal-layer tends to be less than 1% in terms of a number fraction. If the Mg phase is present in the plated-metal-layer, the surface of the plated-metal-layer turns black with the passage of time particularly in a humid environment, and hence the appearance of the plating becomes defective in some cases. In this respect, it is preferable to avoid mixing of the Mg phase into the surface layer of the plated-metal-layer in particular. By storing the plated steel sheet in a thermohygrostat tank for a certain period of time, the occurrence of appearance defectiveness, a phenomenon in which the surface of the plated-metal-layer turns black, can be determined.

Regarding the plated-metal-layer of the plated steel sheet according to the embodiment, when a cross section whose cutting direction is parallel to a thickness direction of the plated-metal-layer is viewed and when a thickness of the plated-metal-layer in the thickness direction is regarded as D in a unit of μm, an area from a surface of the plated-metal-layer toward the steel sheet in the thickness direction to 0.05×D is regarded as an outermost area of the plated-metal-layer, and an area from the interface between the steel sheet and the plated-metal-layer toward the plated-metal-layer in the thickness direction to 0.05×D is regarded as an innermost area of the plated-metal-layer, an area fraction of the coarse domain in the outermost area of the plated-metal-layer (area of coarse domain in outermost area of plated-metal-layer/area of outermost area of plated-metal-layer) is preferably 7% to less than 100% and an area fraction of the coarse domain in the innermost area of the plated-metal-layer (area of coarse domain in innermost area of plated-metal-layer/area of innermost area of plated-metal-layer) is preferably 7% to less than 100%. Furthermore, when an area except for the outermost area and the innermost area in the plated-metal-layer is regarded as a main-body area of the plated-metal-layer, an area fraction of the fine domain in the main-body area of the plated-metal-layer (area of fine domain in main-body area of plated-metal-layer/area of main-body area of plated-metal-layer) is preferably 50% to less than 100%. If the above conditions are satisfied, the constituent phases contained in the plated-metal-layer are preferably arranged, and hence the corrosion resistance of the plated-metal-layer is further improved. In addition, the adherence of the plated-metal-layer tends to be improved. In a case where the grains in the coarse domain are present in a position that extends across the outermost area and the innermost area of the plated-metal-layer, or in a case where the grains in the coarse domain are present in a position that extends across the innermost area and the main-body area of the plated-metal-layer, the aforementioned area fraction may be calculated using the area of the grains included in the outermost area or deep area of the plated-metal-layer. Likewise, in a case where the grains in the fine domain are present in a position that extends across the outermost area and innermost area of the plated-metal-layer, or in a case where the grains in the fine domain are present in a position that extends across the innermost area and the main-body area of the plated-metal-layer, the aforementioned area fraction may be calculated using the area of grains included in the main-body area of the plated-metal-layer.

The plated steel sheet according to the embodiment preferably further has a Fe—Al containing alloy layer (an alloy layer containing Fe—Al). The Fe—Al containing alloy layer is preferably arranged between the steel sheet and the plated-metal-layer and preferably contains at least one or more kinds of compound between Fe₅Al₂ and Al_(3.2)Fe, and a thickness of the Fe—Al containing alloy layer in a thickness direction thereof is preferably 10 nm to 1,000 nm. If the Fe—Al containing alloy layer satisfying the above conditions is arranged in the interface between the steel sheet and the plated-metal-layer, peeling of the plated-metal-layer is preferably inhibited. Furthermore, if the Fe—Al containing alloy layer is formed, the adherence of the plated-metal-layer tends to be improved.

The thickness D of the plated-metal-layer of the plated steel sheet according to the embodiment is not particularly limited, and may be controlled as necessary. Generally, the thickness D is set to be 35 μm smaller in many cases.

The metallographic structure of the plated-metal-layer is observed as below. A sample is collected by cutting the plated steel sheet such that the cross section whose cutting direction is parallel to the thickness direction of the plated steel sheet is observed. The cross section is polished or processed by using a Cross Section Polisher (CP). In a case where the cross section is polished, the cross section is etched with nital. The cross section is then observed using an optical microscope or SEM, and a metallographic micrograph thereof is captured. If the cross section observed with SEM is a COMPO image as shown in FIG. 1, due to a difference in a chemical composition between the coarse domain and the fine domain, a sharp contrast is made, and hence the interface between the coarse domain and the fine domain can be easily discerned. The chemical composition of the constituent phases can be measured by analysis based on EDX or EPMA. From the result of the chemical composition, the constituent phases can be simply identified. The metallographic micrograph is binarized through, for example, image analysis; an area ratio of a white portion or black portion of the plated-metal-layer is measured; and in this way, area fractions of the constituent phases can be measured. Furthermore, from the determined area of each coarse domain, an average equivalent circle diameter can be determined by calculation. Alternatively, by observing the metallographic structure of the plated-metal-layer by an Electron Back Scattering Diffraction Pattern (EBSD) method, the constituent phases may be identified, and the area fraction and the average equivalent circle diameter of the constituent phases may be determined.

In order to more specifically identify the constituent phases, the metallographic structure of the plated-metal-layer is observed as below. A thin sample is collected by cutting the plated steel sheet such that the cross section whose cutting direction is parallel to the thickness direction of the plated steel sheet is observed. The thin sample is subjected to ion milling. Alternatively, a thin sample is collected by processing the plated steel sheet with a Focused Ion Beam (FIB) such that the cross section whose cutting direction is parallel to the thickness direction of the plated steel sheet is observed. These thin samples are observed with TEM, and the metallographic micrograph thereof is captured. The constituent phases can be accurately identified using an electron diffraction pattern. By performing image analysis on the metallographic micrograph, the area fractions and the average equivalent circle diameters of the constituent phases can be determined.

From XRD diffraction peaks of the plated-metal-layer, the existence of the constituent phases can be confirmed in the simplest way, although how the constituent phases exist in a space cannot be ascertained in this way. Here, because the diffraction peak positions of the quasicrystal phase, Mg₅₁Zn₂₀, and Mg₃₂(Zn,Al)₄₉ overlap each other, the existence of theses phases can be confirmed, but it is difficult to distinguish them from each other.

The area fraction and the average equivalent circle diameter of the constituent phase in the plated-metal-layer, for example, the Zn phase, the Al phase, the MgZn phase, the quasicrystal phase, or the Zn—Al eutectic may be determined through EPMA mapping image of three points in a region of 6 μm×100 μm in the aforementioned cross section of the plated-metal-layer.

The steel sheet as a base metal of the plated steel sheet according to the embodiment is not particularly limited. As the steel sheet, it is possible to use Al killed steel, ultra-low carbon steel, high carbon steel, various high tensile strength steel, steel containing Ni or Cr, or the like.

Next, a method of producing a plated steel sheet according to the embodiment will be described.

The method of producing a plated steel sheet according to the embodiment includes a hot-dip-plating process of dipping the steel sheet into a hot-dip-plating bath having an adjusted composition in order to form a plated-metal-layer on a surface of the steel sheet; a first cooling process of cooling the steel sheet after the hot-dip-plating process under conditions such that an average cooling rate of the plated-metal-layer is 15° C./sec to 50° C./sec in a temperature range where a temperature of the plated-metal-layer is from T_(melt)+10° C. to T_(solid-liquid), when T_(melt) in a unit of ° C. is regarded as a liquidus temperature of the plated-metal-layer and when T_(solid-liquid) in a unit of ° C. is a temperature range where the plated-metal-layer is in a coexistence state of a solid phase and a liquid phase and where a volume ratio of the solid phase to the plated-metal-layer (volume of solid phase/volume of plated-metal-layer) is 0.01 to 0.1; and a second cooling process of cooling the steel sheet after the first cooling process under conditions such that an average cooling rate of the plated-metal-layer is 100° C./sec to 3000° C./sec in a temperature range where a temperature of the plated-metal-layer is from a temperature at finishing the first cooling process to 250° C.

A value of T_(melt) which is a liquidus temperature of the plated-metal-layer can be determined using, for example, liquidus temperatures (liquidus surface temperatures) disclosed in a non-patent document (Liang, P., Tarfa, T., Robinson, J. A., Wagner, S., Ochin, P., Harmelin, M. G., Seifert, H. J., Lukas, H. L., Aldinger, F., “Experimental Investigation and Thermodynamic Calculation of the Al—Mg—Zn system”, Thermochim. Acta, 314, 87-110 (1998)) written by Liang et al, as shown in FIG. 7. In this way, a value of T_(melt) substantially can be estimated by using the fraction of Zn, Al, and Mg contained in the plated-metal-layer.

A value of T_(solid-liquid) can be accurately determined from an alloy phase diagram. Specifically, by using the chemical composition of the plated-metal-layer and the corresponding alloy phase diagram, a volume ratio (volume fraction) between a plurality of coexisting phases can be determined based on lever rule. That is, by using the alloy phase diagram, a temperature at which a volume ratio of a solid phase becomes 0.01 and a temperature at which a volume ratio of the solid phase becomes 0.1 may be determined. In the method of producing a plated steel sheet according to the embodiment, the value of T_(solid-liquid) may be determined using the alloy phase diagram. At this time, as the alloy phase diagram, a calculated phase diagram based on a thermodynamic calculation system may be used. Here, because the alloy phase diagram merely shows an equilibrium phase, the ratio between the constituent phases determined from the alloy phase diagram does not necessarily totally agree with an actual ratio between the constituent phases in the plated-metal-layer which is being cooled. Regarding T_(solid-liquid) as a temperature range where the plated-metal-layer that is being cooled is in a coexistence state of a solid phase and a liquid phase and a volume ratio of the solid phase to the plated-metal-layer is 0.01 to 0.1, the inventors of the present invention conducted intensive investigation. As a result, they found that T_(solid-liquid) can be empirically determined by the following expression, {345+0.8×(T_(melt)−345)}−1≦T_(solid-liquid)<T_(melt). Therefore, in the method of producing a plated steel sheet according to the embodiment, a value of T_(solid-liquid) may be determined by the above expression.

In the hot-dip-plating process, the chemical composition of the plating bath is adjusted such that the chemical composition, by atomic %, of the plated-metal-layer formed on the surface of the steel sheet contains Zn: 28.5% to 52%, Al: 0.5% to 10%, Ca: 0% to 3.5%, Y: 0% to 3.5%, La: 0% to 3.5%, Ce: 0% to 3.5%, Si: 0% to 0.5%, Ti: 0% to 0.5%, Cr: 0% to 0.5%, Fe: 0% to 2%, Co: 0% to 0.5%, Ni: 0% to 0.5%, V: 0% to 0.5%, Nb: 0% to 0.5%, Cu: 0% to 0.5%, Sn: 0% to 0.5%, Mn: 0% to 0.2%, Sr: 0% to 0.5%, Sb: 0% to 0.5%, and Pb: 0% to 0.5%, the balance of Mg and impurities.

In the embodiment, the hot-dip-plating process is selected for example. However, the method of forming the plated-metal-layer on the surface of the steel sheet is not limited as long as the plated-metal-layer having the aforementioned chemical composition can be formed on the surface of the steel sheet. In addition to the hot-dip-plating, spraying, sputtering, ion plating, evaporating, or electroplating may be applied.

Immediately after being pulled up out of the plating bath, the plated-metal-layer formed on the surface of the steel sheet by the hot-dip-plating process is in a molten state (liquid phase). By cooling the plated-metal-layer in the molten state by a first cooling process and a second cooling process unique to the embodiment, the plated-metal-layer can be controlled to have the aforementioned metallographic structure containing a quasicrystal.

In a case where a plated-metal-layer forming method other than the hot-dip-plating process is selected, by reheating the plated steel sheet, on which the plated-metal-layer is formed, by using a heating furnace so as to melt only the plated-metal-layer, and then cooling the plated-metal-layer by the first cooling process and the second cooling process unique to the embodiment, the plated-metal-layer can be controlled to have the aforementioned metallographic structure containing a quasicrystal.

A melting point of the plated-metal-layer containing Mg and Zn as main components is totally different from a melting point of the steel sheet as a base metal. Therefore, those skilled in the related art can easily determine an optimized temperature at which only the plated-metal-layer is melted and an optimized melting time.

For example, if being heated to 700° C., the plated-metal-layer is completely melted while the steel sheet as a base metal is not melted. Particularly, rapid heating in a high-temperature atmosphere is preferable because the plated-metal-layer of the plated steel sheet contacting the atmosphere is preferentially heated.

In the hot-dip-plating process, an oxygen concentration of the atmosphere at the time of dipping the steel sheet is preferably 0 ppm to 100 ppm in a volume ratio; a plating tub holding the plating bath is preferably a steel tub; T_(bath) which is a temperature of the plating bath is preferably 10° C. to 100° C. higher than T_(melt); and a time to dip the steel sheet into the plating bath is preferably 1 sec to 10 sec.

When the oxygen concentration is 100 ppm or less in a volume ratio, oxidation of the plating bath can be preferably inhibited. The oxygen concentration is more preferably 50 ppm or less in a volume ratio. When the plating tub is a steel tub, an amount of inclusions in the plating bath is reduced, and hence a quasicrystal is preferably formed in the metallographic structure of the plated-metal-layer. Furthermore, in a case where the plating tube is a steel tub, wearing of the inner walls of the plating tub can be further inhibited than in a case where the plating bath is a ceramic bath. When T_(bath) which is a temperature of the plating bath is 10° C. to 100° C. higher than T_(melt), the plated-metal-layer is preferably formed on the steel sheet, and a Fe—Al containing alloy layer is formed between the steel sheet and the plated-metal-layer. T_(bath) which is a temperature of the plating bath is more preferably 30° C. to 50° C. higher than T_(melt). When the time to dip the steel sheet into the plating bath is 1 sec to 10 sec, the plated-metal-layer is preferably formed on the steel sheet, and a Fe—Al containing alloy layer is formed between the steel sheet and the plated-metal-layer. The time to dip the steel sheet into the plating bath is more preferably 2 sec to 4 sec.

In the first cooling process, it is important to control the average cooling rate of the plated-metal-layer at the time when the temperature of the plated-metal-layer reaches T_(solid-liquid), which is a temperature range where a volume ratio of a solid phase to the inner of the plated-metal-layer (liquid phase+solid phase) is 0.01 to 0.1, from T_(melt)+10° C. as a liquidus temperature of the plated-metal-layer. In the first cooling process, the steel sheet on which the plated-metal-layer is formed is cooled by controlling the average cooling rate within a range of 15° C./sec to 50° C./sec.

On the other hand, the cooling of the first cooling process may be performed under the following conditions. In a case where T_(melt)≧T_(solid-liquid)+10° C. is satisfied, the steel sheet after the hot-dip-plating process may be cooled under conditions such that an average cooling rate of the plated-metal-layer is within a range of 15° C./sec to 50° C./sec in a temperature range where the temperature of the plated-metal-layer reaches T_(solid-liquid) from T_(melt). In a case where T_(melt)<T_(solid-liquid)+10° C. is satisfied, the steel sheet after the hot-dip-plating process may be cooled under conditions such that an average cooling rate of the plated-metal-layer is within a range of 15° C./sec to 50° C./sec in a temperature range where the temperature of the plated-metal-layer reaches T_(solid-liquid) from T_(solid-liquid)+10° C.

By the cooling performed in the first cooling process, at least one or more kinds of the Zn phase, the quasicrystal phase, the MgZn phase, and the Al phase are crystallized as a primary phase in the plated-metal-layer that is in a molten state (liquid phase) before the beginning of cooling. The Zn phase, the quasicrystal phase, the MgZn phase or the Al phase that are crystallized are finally become the constituent phase included in the coarse domain. Here, the Zn phase and the Al phase may form a eutectic structure. It is preferable that the average equivalent circle diameter of a block size of the eutectic structure is larger than 0.2 μm and becomes the coarse domain.

If the average cooling rate in the first cooling process is less than 15° C./sec, a quasicrystal is not easily formed because the average cooling rate does not reach a cooling rate of a quasicrystal phase that is originally formed as a non-equilibrium phase. In addition, the coarse domain which mainly includes the Zn phase, the Al phase, or the MgZn phase is less likely to be formed. In contrast, if the average cooling rate in the first cooling process is higher than 50° C./sec, a quasicrystal phase, a Zn phase, a MgZn phase, and an Al phase, or the like, having an average equivalent circle diameter of less than 0.2 μm are formed too much. Furthermore, in some cases, the coarse domain is not formed, and the aforementioned bimodal structure is not established. In a case where the cooling rate is extremely high, an amorphous phase is formed too much. Therefore, the upper limit of the average cooling rate in the first cooling process is set to be 50° C./sec.

In the first cooling process, in a case where the average cooling rate of the plated-metal-layer is controlled to satisfy the aforementioned conditions from a temperature lower than T_(melt)+10° C. (in a case where it is controlled from a temperature lower than T_(melt) when T_(melt)≧T_(solid-liquid)+10° C. is satisfied, or in a case where it is controlled from a temperature lower than T_(solid-liquid)+10° C. when T_(melt)<T_(solid-liquid)+10° C. is satisfied), the primary phase crystallized in the plated-metal-layer cannot become a Zn phase, a quasicrystal phase, a MgZn phase or an Al phase. Furthermore, in a case where the control of the average cooling rate to satisfy the aforementioned conditions is stopped at a temperature higher than T_(solid-liquid), or in a case where the average cooling rate is controlled to satisfy the aforementioned conditions down to a temperature lower than T_(solid-liquid), the average equivalent circle diameter and the area fraction of the Zn phase, the Al phase, the quasicrystal phase, the MgZn phase, or the Zn—Al eutectic phase cannot be preferably controlled. In addition, in some cases, the metallographic structure cannot be controlled to become a bimodal structure consisting of the coarse domain and the fine domain described above. In a case where the cooling of the first cooling process is performed based on a temperature at which a volume ratio of a solid phase to a liquid phase in the plated-metal-layer does not become 0.01 to 0.1, the average equivalent circle diameter and the area fraction of the Zn phase, the Al phase, or the Zn—Al eutectic phase cannot be preferably controlled. Moreover, in some cases, the metallographic structure cannot be controlled to become a bimodal structure consisting of the coarse domain and the fine domain described above. In the first cooling process, in a case where the average cooling rate of the plated-metal-layer is less than 15° C./sec or more than 50° C./sec, the Zn phase, the Al phase, the quasicrystal phase, the MgZn phase, or the Zn—Al eutectic phase cannot be the coarse domain in some cases.

In the second cooling process, it is important to control the average cooling rate of the plated-metal-layer at the time when the temperature of the plated-metal-layer reaches 250° C. from a temperature at a point in time when the first cooling process ends, that is, from a temperature at finishing the first cooling process that is within T_(solid-liquid). The steel sheet having undergone the first cooling process is cooled by controlling the average cooling rate to become 100° C./sec to 3,000° C./sec. The lower limit of the temperature range is preferably 200° C., more preferably 150° C., and most preferably 100° C.

By the cooling in the second cooling process, in the plated-metal-layer in which a Zn phase, a quasicrystal phase, a MgZn phase, or an Al phase is crystallized as a primary phase and a solid phase and a liquid phase is in a coexistence state, at least one or more kinds of phase among a quasicrystal phase, a Mg₅₁Zn₂₀ phase, a Zn phase, an amorphous phase, or a Mg₃₂(Zn,Al)₄₉ phase that are more fine are crystallized. It is preferable that the crystallized the quasicrystal phase, the Mg₅₁Zn₂₀ phase, the Zn phase, the amorphous phase, or the Mg₃₂(Zn,Al)₄₉ phase finally become constituent phases included in the fine domain.

In the second cooling process, in a case where the average cooling rate is controlled to satisfy the aforementioned conditions from a temperature higher or lower than T_(solid-liquid), the average equivalent circle diameter and the area fraction of the Zn phase, the Al phase, the quasicrystal phase, the MgZn phase, or the Zn—Al eutectic phase cannot be preferably controlled. Furthermore, in some cases, the metallographic structure cannot be controlled to become a bimodal structure consisting of the coarse domain and the fine domain described above. In addition, in a case where the control of the average cooling rate to satisfy the aforementioned conditions is stopped at a temperature higher than 250° C., the quasicrystal phase as a non-equilibrium phase, the Mg₅₁Zn₂₀ phase, and the Mg₃₂(Zn,Al)₄₉ phase undergo phase decomposition in some cases. Moreover, in some cases, the metallographic structure cannot be controlled to become a bimodal structure consisting of the coarse domain and the fine domain described above. In a case where the average cooling rate in the second cooling process is less than 100° C./sec, the quasicrystal phase, the Mg₅₁Zn₂₀ phase, the Zn phase, the amorphous phase, or the Mg₃₂(Zn,Al)₄₉ phase is not formed, or a metallographic structure containing an extremely large amount of Mg phase is established. In addition, the quasicrystal phase, the Mg₅₁Zn₂₀ phase, the Zn phase, the amorphous phase, or the Mg₃₂(Zn,Al)₄₉ phase does not becomes the fine domain in some cases. In a case where the average cooling rate in the second cooling process is greater than 3,000° C./sec, an amorphous phase is formed too much, and hence the metallographic structure cannot be controlled to become the aforementioned bimodal structure in some cases.

As described above, T_(melt) as a liquidus temperature of the plated-metal-layer may be determined from a liquidus surface phase diagram of a ternary Zn—Al—Mg system. T_(solid-liquid) as a temperature range in which a volume ratio of a solid phase to the plated-metal-layer becomes 0.01 to 0.1 may be determined from the following expression. {345+0.8×(T_(melt)−345)}−1≦T_(solid-liquid)<T_(melt). Because the amount of solid phase explosively increases around the temperature range in which the volume ratio of a solid phase to the plated-metal-layer becomes 0.01 to 0.1, the cooling of the first cooling process is finished in the temperature range. By controlling the cooling based on {345+0.8×(T_(melt)−345)}, the average equivalent circle diameter and the area fraction of the constituent phase can be preferably controlled. In this way, in order to form the aforementioned plated-metal-layer, the temperature needs to be accurately controlled.

In a method for actually measuring a temperature of the plated-metal-layer at the time of producing the plated steel sheet according to the embodiment, a contact-type thermocouple (K-type) may be used. By mounting the contact-type thermocouple on an original sheet, an average temperature of the whole plated-metal-layer can be monitored all the time. If a pull-up rate and a thickness are mechanically controlled, and a preheating temperature of the steel sheet, a temperature of the hot-dip plating bath, or the like are standardized, it is possible to substantially accurately monitor a temperature of the whole plated-metal-layer at the point in time under the production conditions. Consequently, the cooling in the first cooling process and the second cooling process can be accurately controlled. A surface temperature of the plated-metal-layer may be measured using a noncontact-type radiation thermometer, although the noncontact-type thermometer is not as accurate as a contact-type.

A relationship between a surface temperature of the plated-metal-layer and an average temperature of the whole plated-metal-layer may be determined by cooling simulation for analyzing thermal conductivity. Specifically, based on each of the production conditions such as a preheating temperature of the steel sheet, a temperature of the hot-dip plating bath, a rate at which the steel sheet is pulled up out of the plating bath, a thickness of the steel sheet, a thickness of the plated-metal-layer, an amount of heat exchanged between the plated-metal-layer and the production facilities, and an amount of heat radiated from the plated-metal-layer, a surface temperature of the plated-metal-layer and an average temperature of the whole plated-metal-layer may be determined, and a relationship between the surface temperature of the plated-metal-layer and the average temperature of the whole plated-metal-layer may be determined. As a result, by actually measuring the surface temperature of the plated-metal-layer at the time of producing the plated steel sheet, the average temperature of the whole plated-metal-layer at the point in time under the production conditions can be inferred. Consequently, the cooling in the first cooling process and the second cooling process can be accurately controlled.

The cooling method in the first cooling process and the second cooling process is not particularly limited. As the cooling method, cooling using a rectified high-pressure gas, mist cooling, or submersion cooling may be performed. Here, in order to preferably control the surface condition of the plated-metal-layer or the formation of the quasicrystal, it is preferable to perform cooling using a rectified high-pressure gas. If H₂ or He is used, the cooling rate is increased.

As the hot-dip plating applied in the embodiment, all of the known plating methods such as a Sendzimir method, a pre-plating method, a two-step plating method, and a flux method can be used. As pre-plating, displacement plating, electroplating, or evaporating, or the like can be used.

In the method of producing a plated steel sheet according to the embodiment, steel used as a base metal of the plated steel sheet is not particularly limited. The aforementioned effects are not affected by the chemical composition of steel, and Al killed steel, ultra-low carbon steel, high carbon steel, various high tensile strength steel, steel containing Ni or Cr, or the like can be used.

In the method of producing a plated steel sheet according to the embodiment, each of the processes such as a steel making process, a hot rolling process, a pickling process, and a cold rolling process that precede the hot-dip plating process is not particularly limited. That is, the production conditions of the steel sheet supplied in the hot-dip plating process or the material of the steel sheet is not particularly limited.

Here, the steel sheet supplied in the hot-dip plating process preferably has a temperature difference between a surface temperature and an internal temperature. Specifically, it is preferable that a surface temperature of the steel sheet immediately before being dipped into the plating bath is higher than an internal temperature thereof. For example, a surface temperature of the steel sheet immediately before being dipped into the plating bath is preferably 10° C. to 50° C. higher than a temperature of the center of the steel sheet in the thickness direction thereof. In this case, immediately after being pulled up out of the plating bath, the plated-metal-layer undergoes heat extraction due to the steel sheet, and accordingly, the plated-metal-layer can be preferably controlled to have the aforementioned metallographic structure containing a quasicrystal. A method for making a temperature difference between the surface temperature and the internal temperature in the steel sheet immediately before being dipped into the plating bath is not particularly limited. For example, the steel sheet immediately before being dipped into the plating bath may be rapidly heated in a high-temperature atmosphere such that only the surface temperature of the steel sheet is controlled to become a temperature preferable for performing hot-dip plating. In this case, because only the surface area of the steel sheet is heated preferentially, the steel sheet can be dipped into the plating bath in a state of having a temperature difference between the surface temperature and the internal temperature.

For evaluating the corrosion resistance of the plated-metal-layer, an exposure test is most preferable which makes it possible to evaluate the corrosion resistance of the plated-metal-layer in a real environment. By evaluating a corrosion loss of the plated-metal-layer for a predetermined period of time, whether the corrosion resistance is excellent or poor can be evaluated.

In a case where plated-metal-layers having high corrosion resistance are compared with each other in terms of corrosion resistance, it is preferable to perform a long-term corrosion resistance test. The corrosion resistance is evaluated based on the time taken for red rust to occur. Furthermore, at the time of evaluating the corrosion resistance, it is important to consider a time period during which the steel sheet is under protection.

In order to evaluate the corrosion resistance in a simpler way, it is possible to use a combined cycle corrosion test or an accelerated corrosion test such as a salt spray test. By evaluating a corrosion loss or a period of time during which the red rust resistance lasts, whether the corrosion resistance is excellent or poor can be determined. In a case where plated-metal-layers having high corrosion resistance are compared with each other in terms of corrosion resistance, it is preferable to use a combined cycle corrosion test using a high-concentration aqueous NaCl solution with a concentration of around 5%. If a low-concentration (1% or less) aqueous NaCl solution is used, it is difficult to determine whether the corrosion resistance is excellent or poor.

The plated-metal-layer may also be subjected to conversion coating using an organic or inorganic material. The plated-metal-layer according to the embodiment contains Zn in an amount of equal to or greater than a certain level. Therefore, the plated-metal-layer according to the embodiment can be subjected to the same conversion coating as performed on a Zn group-plated steel sheet. The same will be applied to painting performed on a film having undergone conversion coating. Furthermore, the plated-metal-layer according to the embodiment can also be used as a base sheet of a laminated steel sheet.

It is considered that the plated steel sheet according to the embodiment can be used particularly in places in a severely corrosive environment. The plated steel sheet according to the embodiment can be used as a substitute for various plated steel sheets used in the fields of building materials, automobiles, consumer electronics, energy, and the like.

Example 1

Next, effects of an aspect of the present invention will be specifically described based on examples. The conditions in the examples are merely an example adopted for checking a possibility of embodying the present invention and effects thereof, and the present invention is not limited to the example conditions. As long as the object of the present invention is achieved, the present invention can adopt various conditions without departing from the gist of the present invention.

Through a hot-dip plating process, a first cooling process, and a second cooling process under the production conditions shown in Tables 1 and 2, a plated steel sheet containing a quasicrystal was produced. A plating bath was obtained by dissolving a predetermined amount of pure metal ingot. The plating bath was covered with a sealing box and then purged with an Ar gas such that an oxygen concentration thereof was controlled to reach a predetermined level.

As a base sheet for plating (steel sheet as a base metal of the plated steel sheet), a hot rolled steel sheet having a thickness of 0.8 mm (carbon content: 0.2% by mass) was used. The steel sheet was cut in 100 mm×200 mm. For hot-dip plating, a batch-type hot-dip plating tester was used. During production, a temperature of a center area of the plated steel sheet was monitored.

Before the steel sheet was dipped into the plating bath, the surface of the steel sheet heated to 800° C. was reduced using a N₂-5% H₂ gas in a furnace in which an oxygen concentration was controlled. The steel sheet was air-cooled using a N₂ gas until a surface temperature of the steel sheet reached a temperature which is 20° C. higher than a temperature of the plating bath, and the steel sheet was dipped into the plating bath for a predetermined time. After being dipped into the plating bath, the steel sheet was pulled up at a pull-up rate of 100 mm/sec. When the steel sheet was pulled up, a rectified high-pressure N₂ gas or a mixed gas of H₂ and N₂ was blown to the steel sheet from an outlet that was a parallel slit, thereby controlling an adhered amount (thickness of a plated-metal-layer) and a cooling rate.

20 (C direction: transverse direction) mm×15 (L direction: rolling direction) mm samples were collected from 10 random sites in the prepared plated steel sheet. By dipping the samples into a 10% aqueous HCl solution for 1 second, an oxide film was removed. A metallographic structure of a cross section (whose cutting direction was parallel to a thickness direction of the plated steel sheet) of each sample was observed with SEM, an equivalent circle diameter or an area fraction of each constituent phase (each grain) was measured, and an average thereof was calculated. The equivalent circle diameter or the area fraction of each constituent phase was determined through image analysis. A chemical composition of each constituent phase was measured through analysis using EPMA.

The metallographic structures of three random samples out of the ten samples were observed with an optical microscope (1,000× magnification), and a Vickers indentation was left at a target site. Base on the Vickers indentation, a 8 mm×8 mm sample was cut off. From each sample, a sample for TEM observation was prepared by cryo-ion milling.

By analyzing an electron diffraction pattern of a main grain observed with TEM, the constituent phase (a quasicrystal, Zn, Al, MgZn, Mg₅₁Zn₂₀, Mg₃₂(Zn,Al)₄₉, an amorphous phase, or the like) contained in the metallographic structure was identified. Furthermore, an equivalent circle diameter or an area fraction of each constituent phase was determined through image analysis, and a chemical composition of each constituent phase was measured through analysis using EDX as necessary. Whether or not the Mg phase exists was determined and checked by XRD. In a case where diffraction intensity of the Mg phase in the XRD diffraction pattern was smaller than a prescribed value, it was determined that the metallographic structure of the plated-metal-layer does not contain the Mg phase.

The corrosion resistance, sacrificial protection, antiglare effect and appearance of the plated steel sheet of the plated-metal-layer were evaluated. As corrosion resistance, a corrosion loss, the occurrence of red rust, the occurrence of white rust, the occurrence of red rust in a processed portion, and corrosion resistance after coating were evaluated.

The corrosion lost was evaluated by a Combined cycle Corrosion Test (CCT) based on a JASO (M609-91) cycle. Specifically, for evaluating the corrosion loss, a 50 mm (C direction)×100 mm (L direction) sample was cut off from the prepared plated steel sheet and subjected to the combined cycle corrosion test. The combined cycle corrosion test (CCT) was performed using a 0.5% aqueous NaCl solution, and a corrosion loss after 150 cycles was evaluated.

In the corrosion lost evaluation, a plated steel sheet resulting in a corrosion loss of less than 20 g/m² was determined as being “Excellent”, a plated steel sheet resulting in a corrosion loss of equal to or greater than 20 g/m² and less than 30 g/m² was determined as being “Good”, and a plated steel sheet resulting in a corrosion loss of equal to or greater than 30 g/m² was determined as being “Poor”. “Excellent” shows that the plated steel sheet is the best in the corrosion loss evaluation.

The occurrence of red rust was evaluated by the aforementioned combined cycle corrosion test (CCT). Specifically, the produced plated steel sheet was subjected to the combined cycle corrosion test (CCT) by using a 5% aqueous NaCl solution, and the number of test cycles in which red rust occurred in an area of greater than 5% of a planar portion of the plated steel sheet was investigated.

In the evaluation of the occurrence of red rust, a plated steel sheet in which the red rust was not confirmed after 300 cycles was determined as being “Excellent”, an plated steel sheet in which the red rust was not confirmed after 150 cycles was determined as being “Very Good”, a plated steel sheet in which the red rust was not confirmed after 100 cycles was determined as being “Good”, and a plated steel sheet in which the red rust was confirmed before the 100th cycle was determined as being “Poor”. “Excellent” shows that the plated steel sheet is the best in the evaluation of the occurrence of red rust.

The occurrence of white rust was evaluated by a Salt Spray Test (SST) based on JIS Z2371: 2000. Specifically, the produced plated steel sheet was subjected to the salt spray test (SST) by using a 5% aqueous NaCl solution, and a time taken for white rust to occur in an area of greater than 5% of a planar portion of the plated steel sheet during the test was investigated.

In the evaluation of the occurrence of white rust, a plated steel sheet in which the white rust was not confirmed after 120 hours was determined as being “Excellent, a plated steel sheet in which the white rust was not confirmed after 24 hours was determined as being “Good”, and a plated steel sheet in which the white rust was confirmed before 24 hours passed was determined as being “Poor”. “Excellent” shows that the plated steel sheet is the best in the evaluation of the occurrence of white rust.

The occurrence of red rust in a processed portion was evaluated by performing an accelerated corrosion test (CCT: Combined cycle Corrosion Test) based on JASO (M609-91) on the plated steel sheet after deep drawing process. Specifically, the produced plated steel sheet was processed in a cup shape by deep drawing process (a cylindrical drawing process) under the condition of a diameter of punch φ is 50 mm, a shoulder of die R is 10 mm, a shoulder of punch R is 10 mm, a draw ratio is 2.0, a blank holding pressure is 0.5 ton. The plated steel sheet was subjected to the accelerated corrosion test, and the number of test cycles in which red rust occurred in an area of greater than 5% of the processed portion of the plated steel sheet was investigated.

In the evaluation of the occurrence of red rust in a processed portion, a plated steel sheet in which the red rust was not confirmed after 60 cycles was determined as being “Excellent”, a plated steel sheet in which the red rust was not confirmed after 30 cycles was determined as being “Good”, and a plated steel sheet in which the red rust was confirmed before 30 cycles passed was determined as being “Poor”. “Excellent” shows that the plated steel sheet is the best in the evaluation of the occurrence of red rust in a processed portion.

The corrosion resistance after coating was evaluated by the test under the following conditions. Specifically, a produced plated steel sheet was treated with zinc phosphate-based conversion coating (Surf dyne: SDS350, manufactured by Nippon Paint Co., Ltd.), and was treated by electrodeposition coating (PN 110 gray: manufactured by Nippon Paint Co., Ltd.). And further, a cut flaw reaching the base steel with a length of 10 mm was applied on the surface of the coated steel sheet with a utility knife. The coated steel sheet having the cut flaw was subjected to the combined cycle corrosion test (JASO M609-91), and was corroded after 240 cycles. The width of a bulging of the coating layer around the cut portion after 240 cycles was evaluated.

In the corrosion resistance after coating evaluation, a plated steel sheet resulting in that there is no blister on a flat portion and the width of a bulging of the coating layer from the cut flaw is within 2 mm after 240 cycles was determined as being “Excellent”, a plated steel sheet resulting in that there is no blister and the width of a bulging of the coating layer from the cut flaw is within 3 mm was determined as being “Very Good”, a plated steel sheet resulting in that there is no blister and the width of a bulging of the coating layer from the cut flaw is within 5 mm was determined as being “Good”, and a plated steel sheet resulting in that there is one or more blister or the width of a bulging of the coating layer from the cut flaw is larger than 5 mm was determined as being “Poor”. Here, “Excellent” shows that the plated steel sheet is the best in the corrosion loss evaluation.

The sacrificial protection was evaluated by an electrochemical technique. Specifically, The produced plated steel sheet was dipped into a 0.5% aqueous NaCl solution, and a corrosion potential of the produced plated steel sheet was measured using a Ag/AgCl reference electrode. In this case, a corrosion potential of Fe is about −0.62 V.

In the evaluation of sacrificial protection, a plated steel sheet in which a corrosion potential was −1.0V to −0.8V with respect to the Ag/AgCl reference electrode was determined as being “Excellent”, and a plated steel sheet in which a corrosion potential was not −1.0V to −0.8V was determined as being “Poor”. “Excellent” shows that a difference in a potential between the plated steel sheet and Fe is small, and an excellent sacrificial protection performance is appropriately demonstrated.

The antiglare effect was evaluated by a spectro-colorimetric method. Usually, it is preferable to visually evaluate the antiglare effect. In this example, it was confirmed in advance that there is a correlation between the result of visual observation and an L* value obtained by a colorimeter, and then the antiglare effect was evaluated by a specular component inclusion (SCI) method by using a spectral colorimeter (D65 light source, 10° visual field). Specifically, an L* value of the produced plated steel sheet was investigated by using a spectral colorimeter CM2500d manufactured by Konica Minolta, Inc under the conditions of a measurement diameter of 8φ, 10° visual field, and a D65 light source.

In the evaluation of the antiglare effect, a plated steel sheet having an L* value of less than 75 was determined as being “Excellent”, and a plated steel sheet having an L* value of equal to or greater than 75 was determined as being “Poor”. “Excellent” shows that the antiglare effect of the plated steel sheet is excellent.

The appearance of the plated steel sheet was evaluated by a test in which the plated steel sheet is stored in a thermohygrostat tank. Specifically, the produced plated steel sheet was stored for 72 hours in a thermohygrostat tank with a temperature of 40° C. and a humidity of 95%, and an area (%) of a portion, which turned black, in a planar portion of the plated steel sheet after storage was investigated.

In the appearance evaluation, a plated steel sheet in which an area of less than 1% of the evaluation area (45 mm×70 mm) turned black was determined as being “Excellent”, a plated steel sheet in which an area of equal to or greater than 1% and less than 3% turned black was determined as being “Good”, and a plated steel sheet in which an area of equal to or greater than 3% turned black was determined as being “Poor”. “Excellent” shows that the plated steel sheet is the best in the appearance evaluation.

The powdering property was evaluated by the amount of change in the mass of the plater steel sheet before and after the cylindrical drawing process. Specifically, a cylindrical drawing process was applied to the produced plated steel sheet in blank of 90φ to punch drawing of 50φ (a drawing ratio is 2.2, a low viscosity oil was applied). After the cylindrical drawing process, a tape peeling was applied to the inner portion of the plated steel sheet, and the change in the mass before and after the test was measured. An average value obtained by the tests of ten times in total was used for the evaluation of the change in the mass.

In the evaluation of the powdering property, a plated steel sheet in which a powdering amount (g/m²) is equal to or less than 1/2000 compared to a plating deposition amount (g/m²) was determined as being “Excellent”, a plated steel sheet in which a powdering amount (g/m²) is equal to or less than 1/1000 compared to a plating deposition amount (g/m²) was determined as being “Good”, a plated steel sheet in which a powdering amount (g/m²) is more than 1/1000 compared to a plating deposition amount (g/m²) was determined as being “Poor”. “Excellent” shows that the plated steel sheet is the best in the evaluation of the powdering property.

The production conditions, the production results, and the evaluation results described above are shown in the Tables 1 to 12. In the tables, an underlined numerical value is a value outside the range of the present invention, and a blank shows that the alloy element was not added intentionally.

All of the plated steel sheets of Examples Nos. 1 to 23 satisfied the range of the present invention and were excellent in the corrosion resistance and the sacrificial protection. In contrast, the plated steel sheets of Comparative Example Nos. 1 to 16 do not satisfy the conditions of the present invention and hence the corrosion resistance or the sacrificial protection thereof was insufficient.

TABLE 1 Production conditions First cooling process Temperature dependent on chemical composition of plated-metal-layer Temper- Second ature cooling process range in Temper- Temper- Temper- which ature ature ature volume actually actually actually Hot-dip-plating process ratio of measured measured Average measured Average Temper- solid phase at the at the cooling at the cooling Atmo- ature Time becomes begining end of rate of end of rate of spheric of for Liquidus 0.01 to 0.1 of cooling in plated- cooling in plated- oxygen plating dipping temper- T_(solid-liquid) cooling in first metal- second metal- concen- Material bath steel ature Upper Lower first cooling cooling layer cooling layer tration of plating T_(bath) sheet T_(melt) limit limit process process ° C. / process ° C. / Classification No. ppm tub ° C. Sec ° C. ° C. ° C. ° C. ° C. sec ° C. sec Comparative 1 15 Steel 400 4 350 350 348 365 349 18 20 250 Example Example 1 18 Steel 420 4 350 350 348 365 349 25 20 1000 Comparative 2 20 Steel 400 3 350 350 348 365 349 23 20 3000 Example Example 2 20 Steel 400 3 350 350 348 365 349 18 20 1000 Example 3 20 Steel 400 3 355 355 352 370 353 20 20 1500 Comparative 3 20 Steel 420 3 355 355 352 370 353 41 20 150 Example Example 4 25 Steel 450 3 355 355 352 370 353 30 20 250 Example 5 20 Steel 420 3 375 375 368 390 369 31 20 1000 Example 6 20 Steel 450 4 360 360 356 375 357 40 20 150 Comparative 4 15 Steel 450 3 400 400 388 415 389 21 20 1000 Example Example 7 10 Steel 450 3 400 400 388 415 389 50 20 200 Example 8 20 Steel 450 4 400 400 388 415 389 45 20 2000 Comparative 5 15 Steel 460 3 420 420 404 435 405 43 20 150 Example Comparative 6 20 Steel 450 3 420 420 404 435 405 35 20 200 Example Comparative 7 20 Steel 430 3 420 420 404 435 405 150 20 90 Example Comparative 8 20 Steel 460 3 430 430 412 445 413 50 20 200 Example Comparative 9 20 Steel 460 3 460 460 412 445 413 42 20 100 Example Example 9 20 Steel 500 4 460 460 436 475 437 50 20 100 Comparative 10 20 Steel 510 3 460 460 436 475 450 3000 20 3000 Example Example 10 20 Steel 500 3 450 450 428 465 429 33 20 250

TABLE 2 Production conditions First cooling process Temperature dependent on chemical composition of plated-metal-layer Temper- Second ature cooling process range in Temper- Temper- Temper- which ature ature ature volume actually actually actually ratio of measured measured Average measured Average Hot-dip-plating process solid phase at the at the cooling at the cooling Atmo- Temper- Time becomes begining end of rate of end of rate of spheric ature for Liquidus 0.01 to 0.1 of cooling in plated- cooling in plated- oxygen of plating dipping temper- T_(solid-liquid) cooling in first metal- second metal- concen- Material bath steel ature Upper Lower first cooling cooling layer cooling layer tration of plating T_(bath) sheet T_(melt) limit limit process process ° C. / process ° C. / Classification No. ppm tub ° C. Sec ° C. ° C. ° C. ° C. ° C. sec ° C. sec Comparative 11 20 Steel 500 3 460 460 436 475 425 30 20 1000 Example Example 11 20 Steel 520 4 470 470 444 485 445 23 20 1000 Comparative 12 20 Steel 520 4 470 470 444 485 445 55 20 3000 Example Example 12 20 Steel 550 3 510 510 476 525 477 28 20 1500 Example 13 20 Steel 560 3 510 510 476 525 476 30 20 200 Example 14 20 Steel 550 3 490 490 460 505 473 40 20 1000 Example 15 20 Steel 550 3 510 510 470 525 477 30 20 200 Example 16 15 Steel 550 4 600 500 468 515 469 38 20 100 Comparative 13 15 Steel 540 3 500 500 468 515 469 13 20 250 Example Example 17 10 Steel 560 3 520 520 484 536 485 15 20 3000 Example 18 20 Steel 550 3 510 510 476 525 477 35 20 1500 Example 19 25 Steel 400 3 350 350 348 365 349 25 20 100 Example 20 18 Steel 420 4 350 350 348 365 349 15 20 3000 Example 21 20 Steel 520 4 470 470 444 485 445 17 20 2000 Example 22 20 Steel 420 3 375 375 368 390 369 16 20 2500 Example 23 25 Steel 400 4 350 350 348 365 349 20 20 2800 Comparative 14 25 Steel 590 3 540 540 500 555 501 42 20 150 Example Comparative 15 Commercially available hot dip galvanizing Example Comparative 16 Single-phase amorphous plated steel sheet starting to be submerged Example at 450° C.

TABLE 3 Production result Plated-metal-layer Chemical composition of plated-metal-layer (at %) Zn At Ca Y La Ce Si Ti Cr Fe Co Ni Classification No. at % at % at % at % at % at % at % at % at % at % at % at % Comparative 1 27 4 1.2 0.1 0.1 Example Example 1 28.5 1.5 0.8 0.2 0.2 Comparative 2 29 4 3.6 0.3 Example Example 2 30 5 1 0.2 0.1 0.2 Example 3 30 2.5 1 0.2 Comparative 3 31 9 0.2 0.1 0.6 0.1 0.3 Example Example 4 32 4 0.2 0.2 0.5 0.1 0.2 Example 5 33 5 0.1 Example 6 34 8 0.2 Comparative 4 35 4.5 3.2 0.3 0.6 Example Example 7 36 8 2.5 0.1 0.3 Example 8 36 3 0.5 0.1 0.2 Comparative 5 37 0.7 0.2 Example Comparative 6 38 0 1.5 0.1 Example Comparative 7 39 2 1 0.2 0.1 Example Comparative 8 40 11 0.7 0.2 Example Comparative 9 40 8 5 0.2 Example Example 9 41 1.2 0.005 0.2 Comparative 10 41.5 3 0.3 Example Example 10 42 5 2.2 0.1 0.1 0.2

TABLE 4 Production result Plated-metal-layer Chemical composition of plated-metal-layer (at %) Zn At Ca Y La Ce Si Ti Cr Fe Co Ni Classification No. at % at % at % at % at % at % at % at % at % at % at % at % Comparative 11 43 1.8 1 1 1 0.2 0.3 Example Example 11 44 6 0.3 0.3 0.1 0.2 0.1 Comparative 12 45 9 0.2 Example Example 12 40 0.5 0.3 Example 13 46 5.5 1 0.3 Example 14 46 3 1.5 0.3 Example 15 47 2.8 1 0.3 Example 16 48 7 0.1 3.4 0.005 0.5 0.2 Comparative 13 49 3.5 0.8 0.2 0.3 0.1 Example Example 17 50 1 3 0.3 Example 18 52 10 3.5 0.3 Example 19 28.5 0.5 0.2 Example 20 29 1 0.2 0.2 Example 21 43 5.8 0.3 0.3 0.1 0.2 0.1 Example 22 32 5.5 0.3 Example 23 28.6 0.6 0.2 Comparative 14 54 1 3 0.6 Example Comparative 15 Commercially available hot dip galvanizing Example Comparative 16 Single-phase amorphous plated steel sheet starting to be submerged Example at 450° C.

TABLE 5 Production result Plated-metal-layer Chemical composition of plated-metal-layer (at %) Value of Value of Value Ca + Y + Si + Ti + of V Nb Cu Sn Mn Sr Sb Pb Mg La + Ce Cr Zn + Al Classification No. at % at % at % at % at % at % at % at % at % at % at % at % Comparative 1 67.6 1.3 0 31 Example Example 1 0.1 68.7 1 0 30 Comparative 2 63.1 3.6 0 33 Example Example 2 0.1 0.1 63.3 1.2 0.1 35 Example 3 66.3 1.2 0.1 35 Comparative 3 58.7 0.3 0.7 40 Example Example 4 0.1 0.2 62.5 0.9 0.1 36 Example 5 0.1 0.1 61.4 0 0 38 Example 6 0.1 0.1 57.6 0 0 42 Comparative 4 58.4 3.2 0 39.5 Example Example 7 0.1 53.0 2.5 0.1 44 Example 8 60.2 0.5 0.1 39 Comparative 5 0.6 61.5 0 0 37.7 Example Comparative 6 0.1 60.3 1.5 0 38 Example Comparative 7 57.7 1.2 0 41 Example Comparative 8 48.1 0.7 0 51 Example Comparative 9 0.1 46.7 5 0 48 Example 57.6 0 0.005 42.2 Example 9 Comparative 10 55.2 0 0 44.5 Example Example 10 50.4 2.2 0.2 47

TABLE 6 Production result Plated-metal-layer Chemical composition of plated-metal-layer (at %) Value of Value of Value Ca + Y + Si + Ti + of V Nb Cu Sn Mn Sr Sb Pb Mg La + Ce Cr Zn + Al Classification No. at % at % at % at % at % at % at % at % at % at % at % at % Comparative 11 51.7 3 0 44.8 Example Example 11 49.0 0.6 0.1 50 Comparative 12 45.8 0 0 54 Example Example 12 53.2 0 0 40.5 Example 13 0.1 0.1 47.0 1 1 51.5 Example 14 0.3 0.1 0.1 48.7 1.5 0 49 Example 15 48.9 1 0 49.8 Example 16 40.3 3.5 0.005 55 Comparative 13 46.1 0.8 0.2 52.5 Example Example 17 0.5 0.5 44.7 3 0 51 Example 18 0.005 0.3 33.9 3.5 0 82 Example 19 70.8 0 0 29 Example 20 69.6 0.2 0 30 Example 21 50.2 0.6 0.1 48.8 Example 22 0.1 0.1 61.9 0 0 37.5 Example 23 70.6 0 0 29.2 Comparative 14 41.4 3 0 55 Example Comparative 15 Commercially available hot dip galvanizing Example Comparative 16 Single-phase amorphous plated steel sheet starting to be submerged Example at 450° C.

TABLE 7 Production result Plated-metal-layer Metallographic structure of plated-metal-layer Bimodal structure Coarse domain Area fraction Area Area Area fraction in fraction in Quasicrystal Presence fraction outermost innermost Constituent phase Average Presence or in area of area of Area equivalent Value or absence plated- plated- plated- fraction Presence circle of Mg/ absence of metal- metal- metal- in coarse or diameter (Zn + of Mg bimodal layer layer layer domain Classification No. absence μm Al) phase structure % % % Type % Comparative 1 Absent — — Present Absent — — — — — Example Example 1 Present 0.21 0.58 Absent Present 7 60 51 Quasicrystal/ 79/20 Zn—Al eutectic Comparative 2 Absent — — Absent Absent — — — — — Example Example 2 Present 0.62 0.67 Absent Present 9 45 50 Quasicrystal/ 88/11 Zn—Al eutectic Example 3 Present 0.21 0.63 Absent Present 8.5 58 60 Quasicrystal/ 69/30 Zn—Al eutectic Comparative 3 Absent — — Absent Absent — — — — — Example Example 4 Present 0.4 0.64 Absent Present 12 68 70 Quasicrystal/ 55/25/19 Zn—Al eutectic/ MgZn Example 5 Present 0.6 0.66 Absent Present 9 48 69 Quasicrystal/ 84/15 Zn—Al eutectic Example 6 Present 0.75 0.68 Absent Present 16 72 90 Quasicrystal/ 59/40 Zn—Al eutectic Comparative 4 Absent — — Absent Absent — — — — — Example Example 7 Present 0.95 0.70 Absent Present 15 70 91 Quasicrystal/ 66/33 Zn—Al eutectic Example 8 Present 0.21 0.60 Absent Present 10 75 84 Quasicrystal/ 70/25 Zn—Al eutectic Comparative 5 Absent — — Absent Absent — — — — — Example Comparative 6 Absent — — Absent Absent — — — — — Example Comparative 7 Absent — — Absent Absent — — — — — Example Comparative 8 Present 1.5 0.82 Absent Present 42 58 56 Quasicrystal/Al 89/10 Example Comparative 9 Absent — — Present Absent — — — — — Example Example 9 Present 0.25 0.60 Absent Present 7 38 90 Quasicrystal/ 80/10 MgZn Comparative 10 Absent — — Absent Absent — — — — — Example Example 10 Present 1 0.64 Absent Present 20 90 78 Quasicrystal/ 74/15 Zn—Al eutectic

TABLE 8 Production result Plated-metal-layer Metallographic structure of plated-metal-layer Bimodal structure Coarse domain Area fraction Area Area Area fraction in fraction in Quasicrystal Presence fraction outermost innermost Constituent phase Average Presence or in area of area of Area equivalent or absence plated- plated- plated- fraction in Presence circle Value of absence of metal- metal- metal- coarse or diameter Mg/ of Mg bimodal layer layer layer domain Classification No. absence μm (Zn +Al) phase structure % % % Type % Comparative 11 Present 1.75 0.66 Absent Present 40 86 83 Quasicrystal/MgZn 93/3  Example Example 11 Present 0.95 0.69 Absent Present 26 98 99 Quasicrystal/Zn—Al eutectic 64/35 Comparative 12 Absent — — Absent Absent — — — — — Example Example 12 Present 0.21 0.62 Absent Present 8 80 68 Quasicrystal/Zn 69/30 Example 13 Present 0.7 0.64 Absent Present 12 80 58 Quasicrystal/Zn—Al eutectic 59/40 Example 14 Present 0.23 0.67 Absent Present 18 67 52 Quasicrystal/Zn—Al eutectic 75/24 Example 15 Present 0.35 0.69 Absent Present 9 70 78 Quasicrystal/Zn 71/28 Example 16 Present 0.95 0.73 Absent Present 45 89 98 Quasicrystal/ 54/45 Comparative 13 Absent — — Absent Absent — — — — — Example Example 17 Present 0.21 0.67 Absent Present 9 65 80 Quasicrystal/MgZn 81/4  Example 18 Present 0.95 0.82 Absent Present 34 98 99 Zn—Al eutectic/Quasicrystal 52/47 Example 19 Present 0.21 0.63 Present Present 8 53 49 Quasicrystal/MgZn/Mg 80/18/1 Example 20 Present 0.16 0.67 Absent Present 5 45 43 MgZn/Zn 65/25 Example 21 Present 0.18 0.63 Absent Present 12 58 59 Zn—Al eutectic/Quasicrystal 56/43 Example 22 Present 0.17 0.56 Absent Present 9 45 59 ZnAl eutectic 72 Example 23 Present 0.16 0.67 Present Present 7 49 47 MgZn/Mg 38/1  Comparative 14 Absent — — Absent Absent — — — — — Example Comparative 15 Commercially available hot dip galvanizing Example Comparative 16 Single-phase amorphous plated steel sheet starting to be submerged Example at 450° C.

TABLE 9 Production result Plated-metal-layer Metallographic structure of plated-metal-layer Bimodal structure Fine domain Area fraction Fe—Al containing alloy layer Area Constituent phase Thickness Constituent Thickness Area fraction in Area D of phase of Fe—Al fraction in center area fraction plated- contained containing plated- of plated- in fine metal- Presence in Fe—Al alloy metal- metal- domain layer of containing layer Classification No. layer % layer % Type % μm absence alloy layer nm Comparative 1 — — — — 18 Present Fe₆Al₂/Al₃₂Fe 30 Example Example 1 93 93 Mg₅₁Zn₂₀ 99 15 Present Fe₆Al₂/Al₃₂Fe 30 Comparative 2 — — — — 15 Present Fe₆Al₂/Al₃₂Fe 30 Example Example 2 91 95 Mg₅₁Zn₂₀ 97 18 Present Fe₆Al₂/Al₃₂Fe 30 Example 3 91.5 97 Mg₅₁Zn₂₀ 89 13 Present Fe₆Al₂/Al₃₂Fe 30 Comparative 3 — — — — 15 Present Fe₆Al₂/Al₃₂Fe 30 Example Example 4 88 94 Mg₅₁Zn₂₀ 99 16 Present Fe₆Al₂/Al₃₂Fe 30 Example 5 91 97 Mg₅₁Zn₂₀/Zn 94/5 10 Present Fe₆Al₂/Al₃₂Fe 20 Example 6 84 91 Mg₅₁Zn₂₀ 99 13 Present Fe₆Al₂/Al₃₂Fe 30 Comparative 4 — — — — 15 Present Fe₆Al₂/Al₃₂Fe 30 Example Example 7 85 92 Mg₅₁Zn₂₀ 99 15 Present Fe₆Al₂/Al₃₂Fe 30 Example 8 90 98 Mg₅₁Zn₂₀ 99 12 Present Fe₆Al₂/Al₃₂Fe 20 Comparative 5 — — — — 15 Absent — — Example Comparative 6 — — — — 15 Absent — — Example Comparative 7 — — — — 13 Present Fe₆Al₂/Al₃₂Fe 30 Example Comparative 8 58 60 Mg₅₁Zn₂₀/ 90/9 14 Present Fe₆Al₂/Al₃₂Fe 20 Example Mg32(ZnAl)₄₉ Comparative 9 — — — — 15 Present Fe₆Al₂/Al₃₂Fe 20 Example Example 9 93 99 Mg₅₁Zn₂₀ 99 16 Present Fe₆Al₂/Al₃₂Fe 20 Comparative 10 — — — — 14 Present Fe₆Al₂/Al₃₂Fe 20 Example Example 10 80 87 Mg₅₁Zn₂₀ 99 11 Present Fe₆Al₂/Al₃₂Fe 20

TABLE 10 Production result Plated-metal-layer Metallographic structure of plated-metal-layer Bimodal structure Fine domain Area fraction Fe—Al containing alloy layer Area Constituent phase Thickness Constituent Thickness Area fraction in Area D of phase of Fe—Al fraction in center area fraction plated- contained containing plated- of plated- in fine metal- Presence in Fe—Al alloy metal- metal- domain layer of containing layer Classification No. layer % layer % Type % μm absence alloy layer nm Comparative 11 60 65 Mg₅₁Zn₂₀ 99 13 Present Fe₆Al₂/Al₃₂Fe 20 Example Example 11 74 82 Mg₅₁Zn₂₀/ 95/6  16 Present Fe₆Al₂/Al₃₂Fe 20 Mg32(ZnAl)₄₉ Comparative 12 — — — — 12 Present Fe₆Al₂/Al₃₂Fe 20 Example Example 12 92 98 Mg₅₁Zn₂₀/Zn 84/15 13 Absent — — Example 13 88 93 Mg₅₁Zn₂₀/Zn 86/12 15 Present Fe₆Al₂/Al₃₂Fe 20 Example 14 82 87 Mg₅₁Zn₂₀ 94 13 Present Fe₆Al₂/Al₃₂Fe 30 Example 15 91 98 Mg₅₁Zn₂₀/Zn 80/19 12 Present Fe₆Al₂/Al₃₂Fe 20 Example 16 55 60 Mg₅₁Zn₂₀/Zn 86/13 16 Present Fe₆Al₂/Al₃₂Fe 20 Comparative 13 — — — — 15 Present Fe₆Al₂/Al₃₂Fe 30 Example Example 17 91 98 Mg51Zn20/Zn/ 92/16/1 12 Absent — — Amorphous Example 18 66 73 Mg₅₁Zn₂₀ 99 18 Present Fe₆Al₂/Al₃₂Fe 40 Example 19 92 97 Mg₅₁Zn₂₀ 99 18 Absent — — Example 20 95 99 Mg51Zn20/ 94/4/1 12 Absent — — Quasicrystal/ Amorphous Example 21 88 93 Mg₅₁Zn₂₀/ 94/5  16 Present Fe₆Al₂/Al₃₂Fe 20 Mg32(ZnAl)₄₉ Example 22 91 96 Mg51Zn20/ 92/4/3 10 Present Fe₆Al₂/Al₃₂Fe 20 Quasicrystal Example 23 93 98 Mg51Zn20/ 93/3/1 18 Absent — — Quasicrystal/ Amorphous Comparative 14 — — — — 15 Absent — — Example Comparative 15 Commercially available hot dip galvanizing Example Comparative 16 Single-phase amorphous plated steel sheet starting to be submerged Example at 450° C.

TABLE 11 Evaluation result Evaluation of corrosion resistance Evaluation Evaluation of red rust Evaluation of Evaluation Processed Evaluation of corrosion occurrence portion Corrosion of appearance resistance Corrosion Evaluation of white (Deep loss after sacrificial Antiglare (storage after Classification No. Loss of red rust rust drawing) coating protection effect test powdering Comparative 1 Poor Poor Poor Poor Poor Poor Poor Poor Poor Example Example 1 Good Excellent Good Excellent Excellent Good Excellent Good Excellent Comparative 2 Poor Poor Poor Poor Poor Poor Poor Good Poor Example Example 2 Good Excellent Excellent Excellent Excellent Good Excellent Good Good Example 3 Good Excellent Good Excellent Excellent Good Poor Good Excellent Comparative 3 Poor Poor Poor Poor Poor Poor Poor Good Poor Example Example 4 Good Excellent Excellent Excellent Excellent Good Excellent Good Excellent Example 5 Excellent Excellent Excellent Good Good Good Poor Excellent Excellent Example 6 Excellent Good Good Good Good Good Excellent Excellent Good Comparative 4 Poor Poor Poor Poor Poor Poor Poor Excellent Poor Example Example 7 Excellent Excellent Excellent Excellent Very Good Good Excellent Excellent Good Example 8 Excellent Excellent Excellent Excellent Excellent Good Poor Excellent Excellent Comparative 5 Poor Poor Poor Poor Poor Poor Excellent Excellent Poor Example Comparative 6 Poor Excellent Poor Poor Poor Poor Poor Excellent Poor Example Comparative 7 Poor Poor Poor Poor Poor Poor Poor Poor Poor Example Comparative 8 Excellent Excellent Excellent Poor Poor Excellent Poor Excellent Good Example Comparative 9 Poor Poor Poor Poor Poor Poor Poor Excellent Poor Example Example 9 Excellent Good Excellent Excellent Excellent Good Excellent Poor Excellent Comparative 10 Poor Poor Poor Poor Poor Poor Poor Excellent Excellent Example Example 10 Excellent Excellent Excellent Good Good Very Good Poor Excellent Good

TABLE 12 Evaluation result Evaluation of corrosion resistance Evaluation Evaluation of red rust Evaluation of Evaluation Processed Evaluation of corrosion occurrence portion Corrosion of appearance resistance Corrosion Evaluation of white (Deep loss after sacrificial Antiglare (storage after Classification No. Loss of red rust rust drawing) coating protection effect test powdering Comparative 11 Excellent Excellent Excellent Poor Poor Excellent Poor Excellent Excellent Example Example 11 Excellent Excellent Excellent Good Good Excellent Poor Excellent Excellent Comparative 12 Poor Poor Poor Poor Poor Poor Poor Excellent Poor Example Example 12 Excellent Good Good Excellent Excellent Good Poor Excellent Excellent Example 13 Excellent Excellent Good Excellent Very Good Good Excellent Excellent Good Example 14 Excellent Excellent Good Excellent Excellent Good Excellent Excellent Excellent Example 15 Excellent Excellent Good Excellent Excellent Good Poor Excellent Excellent Example 16 Excellent Excellent Good Good Good Excellent Excellent Excellent Good Comparative 13 Poor Poor Poor Poor Poor Poor Poor Excellent Poor Example Example 17 Excellent Excellent Excellent Excellent Excellent Good Poor Excellent Excellent Example 18 Excellent Excellent Excellent Good Good Excellent Excellent Excellent Good Example 19 Good Good Good Good Good Good Poor Poor Excellent Example 20 Good Good Good Good Good Good Poor Poor Excellent Example 21 Excellent Excellent Excellent Good Good Excellent Poor Excellent Good Example 22 Excellent Excellent Excellent Good Good Good Poor Excellent Excellent Example 23 Good Good Good Good Good Good Poor Poor Excellent Comparative 14 Poor Poor Poor Poor Poor Poor Poor Excellent Poor Example Comparative 15 Poor Poor Poor Poor Poor Poor Poor Excellent Excellent Example Comparative 16 Poor Poor Poor Poor Poor Poor Poor Poor Poor Example

INDUSTRIAL APPLICABILITY

According to the above aspects of the present invention, it is possible to provide the plated steel sheet which is further excellent in the corrosion resistance requested for applying building materials, automobiles, consumer electronics or the like. Therefore, it is possible to prolong the useful life of the materials as compared with the conventional surface-treated steel sheets. Accordingly, the present invention has significant industrial applicability.

BRIEF DESCRIPTION OF THE REFERENCE SYMBOLS

-   -   1: STEEL SHEET     -   2: PLATED-METAL-LAYER     -   2 a: COARSE DOMAIN     -   2 b: FINE DOMAIN     -   2 a 1, 2 a 2, 2 b 1, 2 b 2: LOCAL AREA 

1. A plated steel sheet with a quasicrystal, comprising a steel sheet and a plated-metal-layer arranged on a surface of the steel sheet, wherein: the plated-metal-layer comprises, as a chemical composition, by atomic %, 28.5% to 52% of Zn, 0.5% to 10% of Al, 0% to 3.5% of Ca, 0% to 3.5% of Y, 0% to 3.5% of La, 0% to 3.5% of Ce, 0% to 0.5% of Si, 0% to 0.5% of Ti, 0% to 0.5% of Cr, 0% to 2% of Fe, 0% to 0.5% of Co, 0% to 0.5% of Ni, 0% to 0.5% of V, 0% to 0.5% of Nb, 0% to 0.5% of Cu, 0% to 0.5% of Sn, 0% to 0.2% of Mn, 0% to 0.5% of Sr, 0% to 0.5% of Sb, 0% to 0.5% of Pb, and a balance of Mg and impurities; the plated-metal-layer includes, as a metallographic structure, a quasicrystal phase; a magnesium content, a zinc content, and an aluminum content expressed in atomic % in the quasicrystal phase satisfy 0.5≦Mg/(Zn+Al)≦0.83; and an average equivalent circle diameter of the quasicrystal phase is equal to or larger than 0.01 μm and equal to or smaller than 1 μm.
 2. The plated steel sheet with a quasicrystal according to claim 1, wherein a calcium content, an yttrium content, a lanthanum content, and a cerium content expressed in atomic % in the chemical composition of the plated-metal-layer satisfy 0.3%≦Ca+Y+La+Ce≦3.5%.
 3. The plated steel sheet with a quasicrystal according to claim 1, wherein a silicon content, a titanium content, and a chromium content expressed in atomic % in the chemical composition of the plated-metal-layer satisfy 0.005%≦Si+Ti+Cr≦0.5%.
 4. The plated steel sheet with a quasicrystal according to claim 1, wherein a zinc content and an aluminum content expressed in atomic % in the chemical composition of the plated-metal-layer satisfy 30%≦Zn+Al≦52%.
 5. The plated steel sheet with a quasicrystal according to claim 1, wherein: when viewed in a cross section, whose cutting direction is parallel to a thickness direction of the plated-metal-layer, the metallographic structure of the plated-metal-layer is a bimodal structure which comprises a fine domain composed of a grain having an equivalent circle diameter of 0.2 μm or smaller and a coarse domain composed of a grain having an equivalent circle diameter of larger than 0.2 μm; the coarse domain comprises at least one selected from the quasicrystal phase, a Zn phase, an Al phase and a MgZn phase; the fine domain comprises at least one selected from a Mg₅₁Zn₂₀ phase, a Zn phase, an amorphous phase, a Mg₃₂(Zn,Al)₄₉ phase; and the average equivalent circle diameter of the quasicrystal phase is larger than 0.2 μm and equal to or smaller than 1 μm.
 6. The plated steel sheet with a quasicrystal according to claim 1, wherein: when viewed in a cross section, whose cutting direction is parallel to a thickness direction of the plated-metal-layer, the metallographic structure of the plated-metal-layer is a bimodal structure which comprises a fine domain composed of a grain having an equivalent circle diameter of 0.2 μm or smaller and a coarse domain composed of a grain having an equivalent circle diameter of larger than 0.2 μm; the coarse domain comprises at least one selected from a Zn phase, an Al phase and a MgZn phase; the fine domain comprises at least one selected from the quasicrystal phase, a Mg₅₁Zn₂₀ phase, a Zn phase, an amorphous phase, a Mg₃₂(Zn,Al)₄₉ phase; and the average equivalent circle diameter of the quasicrystal phase is equal to or larger than 0.01 μm and equal to or smaller than 0.2 μm.
 7. The plated steel sheet with a quasicrystal according to claim 5, wherein an area fraction of the coarse domain in the metallographic structure is equal to or more than 5% and equal to or less than 50%, and an area fraction of the fine domain in the metallographic structure is equal to or more than 50% and equal to or less than 95%.
 8. The plated steel sheet with a quasicrystal according to claim 6, wherein an area fraction of the coarse domain in the metallographic structure is equal to or more than 5% and equal to or less than 50%, and an area fraction of the fine domain in the metallographic structure is equal to or more than 50% and equal to or less than 95%.
 9. The plated steel sheet with a quasicrystal according to claim 5, wherein an area fraction of the quasicrystal phase included in the coarse domain is equal to or more than 80% and less than 100% in the coarse domain, and an area fraction in total of the Mg₅₁Zn₂₀ phase, the Zn phase, the amorphous phase, and the Mg₃₂(Zn,Al)₄₉ phase included in the fine domain is equal to or more than 80% and less than 100% in the fine domain.
 10. The plated steel sheet with a quasicrystal according to claim 6, wherein an area fraction in total of the Zn phase, the Al phase, and the MgZn phase included in the coarse domain is equal to or more than 80% and less than 100% in the coarse domain, and an area fraction of the quasicrystal phase included in the fine domain is more than 0% and less than 10% in the fine domain.
 11. The plated steel sheet with a quasicrystal according to claim 5, wherein, when viewed in the cross section and when a thickness of the plated-metal-layer is regarded as D, an area from a surface of the plated-metal-layer toward the steel sheet in the thickness direction to 0.05×D is regarded as an outermost area of the plated-metal-layer, and an area from an interface between the steel sheet and the plated-metal-layer toward the plated-metal-layer in the thickness direction to 0.05×D is regarded as an innermost area of the plated-metal-layer, an area fraction of the coarse domain in the outermost area of the plated-metal-layer is equal to or more than 7% and less than 100% and an area fraction of the coarse domain in the innermost area of the plated-metal-layer is equal to or more than 7% and less than 100%, and when an area except for the outermost area and the innermost area of the plated-metal-layer is regarded as a main-body area of the plated-metal-layer, an area fraction of the fine domain in the main-body area of the plated-metal-layer is equal to or more than 50% and less than 100%.
 12. The plated steel sheet with a quasicrystal according to claim 6, wherein, when viewed in the cross section and when a thickness of the plated-metal-layer is regarded as D, an area from a surface of the plated-metal-layer toward the steel sheet in the thickness direction to 0.05×D is regarded as an outermost area of the plated-metal-layer, and an area from an interface between the steel sheet and the plated-metal-layer toward the plated-metal-layer in the thickness direction to 0.05×D is regarded as an innermost area of the plated-metal-layer, an area fraction of the coarse domain in the outermost area of the plated-metal-layer is equal to or more than 7% and less than 100% and an area fraction of the coarse domain in the innermost area of the plated-metal-layer is equal to or more than 7% and less than 100%, and when an area except for the outermost area and the innermost area of the plated-metal-layer is regarded as a main-body area of the plated-metal-layer, an area fraction of the fine domain in the main-body area of the plated-metal-layer is equal to or more than 50% and less than 100%.
 13. The plated steel sheet with a quasicrystal according to claim 1, wherein a Mg phase is absent in the metallographic structure of the plated-metal-layer.
 14. The plated steel sheet with a quasicrystal according to claim 1, further comprising a Fe—Al containing alloy layer, wherein the Fe—Al containing alloy layer is arranged between the steel sheet and the plated-metal-layer, the Fe—Al containing alloy layer comprises at least one selected from Fe₅Al₂ and Al_(3.2)Fe, and a thickness of the Fe—Al containing alloy layer is equal to or more than 10 nm and equal to or less than 1000 nm.
 15. A method of producing a plated steel sheet with a quasicrystal according to claim 1, comprises: a hot-dip-plating process of dipping a steel sheet into a hot-dip-plating bath having an adjusted composition in order to form a plated-metal-layer on a surface of the steel sheet; a first cooling process of cooling the steel sheet after the hot-dip-plating process under conditions such that an average cooling rate of the plated-metal-layer is equal to or faster than 15° C./sec and equal to or slower than 50° C./sec in a temperature range where a temperature of the plated-metal-layer is from T_(melt)+10° C. to T_(solid-liquid), when the T_(melt) in unit of ° C. is regarded as a liquidus temperature of the plated-metal-layer and when the T_(solid-liquid) in unit of ° C. is a temperature range where the plated-metal-layer is in a coexistence state of a solid phase and a liquid phase and where a volume ratio of the solid phase to the plated-metal-layer is equal to or more than 0.01 and equal to or less than 0.1; and a second cooling process of cooling the steel sheet after the first cooling process under conditions such that an average cooling rate of the plated-metal-layer is equal to or faster than 100° C./sec and equal to or slower than 3000° C./sec in a temperature range where a temperature of the plated-metal-layer is from a temperature at finishing the first cooling process to 250° C.
 16. A method of producing a plated steel sheet with a quasicrystal according to claim 15, in the hot-dip-plating process: wherein an oxygen concentration of an atmosphere at dipping the steel sheet is 100 ppm or less in volume ratio; a plating tub to hold the hot-dip-plating bath is a steel tub; T_(bath) which is a temperature of the hot-dip-plating bath is equal to or higher than 10° C. and equal to or lower than 100° C. higher than the T_(melt); and a time for dipping the steel sheet into the hot-dip-plating bath is equal to or longer than 1 sec and equal to or shorter than 10 sec.
 17. A method of producing a plated steel-sheet with a quasicrystal according to claim 2, comprises: a hot-dip-plating process of dipping a steel sheet into a hot-dip-plating bath having an adjusted composition in order to form a plated-metal-layer on a surface of the steel sheet; a first cooling process of cooling the steel sheet after the hot-dip-plating process under conditions such that an average cooling rate of the plated-metal-layer is equal to or faster than 15° C./sec and equal to or slower than 50° C./sec in a temperature range where a temperature of the plated-metal-layer is from T_(melt)+10° C. to T_(solid-liquid), when the T_(melt) in unit of ° C. is regarded as a liquidus temperature of the plated-metal-layer and when the T_(solid-liquid) in unit of ° C. is a temperature range where the plated-metal-layer is in a coexistence state of a solid phase and a liquid phase and where a volume ratio of the solid phase to the plated-metal-layer is equal to or more than 0.01 and equal to or less than 0.1; and a second cooling process of cooling the steel sheet after the first cooling process under conditions such that an average cooling rate of the plated-metal-layer is equal to or faster than 100° C./sec and equal to or slower than 3000° C./sec in a temperature range where a temperature of the plated-metal-layer is from a temperature at finishing the first cooling process to 250° C.
 18. A method of producing a plated steel sheet with a quasicrystal according to claim 3, comprises: a hot-dip-plating process of dipping a steel sheet into a hot-dip-plating bath having an adjusted composition in order to form a plated-metal-layer on a surface of the steel sheet; a first cooling process of cooling the steel sheet after the hot-dip-plating process under conditions such that an average cooling rate of the plated-metal-layer is equal to or faster than 15° C./sec and equal to or slower than 50° C./sec in a temperature range where a temperature of the plated-metal-layer is from T_(melt)+10° C. to T_(solid-liquid), when the T_(melt) in unit of ° C. is regarded as a liquidus temperature of the plated-metal-layer and when the T_(solid-liquid) in unit of ° C. is a temperature range where the plated-metal-layer is in a coexistence state of a solid phase and a liquid phase and where a volume ratio of the solid phase to the plated-metal-layer is equal to or more than 0.01 and equal to or less than 0.1; and a second cooling process of cooling the steel sheet after the first cooling process under conditions such that an average cooling rate of the plated-metal-layer is equal to or faster than 100° C./sec and equal to or slower than 3000° C./sec in a temperature range where a temperature of the plated-metal-layer is from a temperature at finishing the first cooling process to 250° C.
 19. A method of producing a plated steel sheet with a quasicrystal according to claim 4, comprises: a hot-dip-plating process of dipping a steel sheet into a hot-dip-plating bath having an adjusted composition in order to form a plated-metal-layer on a surface of the steel sheet; a first cooling process of cooling the steel sheet after the hot-dip-plating process under conditions such that an average cooling rate of the plated-metal-layer is equal to or faster than 15° C./sec and equal to or slower than 50° C./sec in a temperature range where a temperature of the plated-metal-layer is from T_(melt)+10° C. to T_(solid-liquid), when the T_(melt) in unit of ° C. is regarded as a liquidus temperature of the plated-metal-layer and when the T_(solid-liquid) in unit of ° C. is a temperature range where the plated-metal-layer is in a coexistence state of a solid phase and a liquid phase and where a volume ratio of the solid phase to the plated-metal-layer is equal to or more than 0.01 and equal to or less than 0.1; and a second cooling process of cooling the steel sheet after the first cooling process under conditions such that an average cooling rate of the plated-metal-layer is equal to or faster than 100° C./sec and equal to or slower than 3000° C./sec in a temperature range where a temperature of the plated-metal-layer is from a temperature at finishing the first cooling process to 250° C.
 20. A method of producing a plated steel sheet with a quasicrystal according to claim 5, comprises: a hot-dip-plating process of dipping a steel sheet into a hot-dip-plating bath having an adjusted composition in order to form a plated-metal-layer on a surface of the steel sheet; a first cooling process of cooling the steel sheet after the hot-dip-plating process under conditions such that an average cooling rate of the plated-metal-layer is equal to or faster than 15° C./sec and equal to or slower than 50° C./sec in a temperature range where a temperature of the plated-metal-layer is from T_(melt)+10° C. to T_(solid-liquid), when the T_(melt) in unit of ° C. is regarded as a liquidus temperature of the plated-metal-layer and when the T_(solid-liquid) in unit of ° C. is a temperature range where the plated-metal-layer is in a coexistence state of a solid phase and a liquid phase and where a volume ratio of the solid phase to the plated-metal-layer is equal to or more than 0.01 and equal to or less than 0.1; and a second cooling process of cooling the steel sheet after the first cooling process under conditions such that an average cooling rate of the plated-metal-layer is equal to or faster than 100° C./see and equal to or slower than 3000° C./sec in a temperature range where a temperature of the plated-metal-layer is from a temperature at finishing the first cooling process to 250° C. 